Case Study: Leading Injection Molding Company achieves cost-effective, reliable machine design with Maplesoft MapleSim

Using Virtual Commissioning for a New, Competitive Injection Molding Machine

Leading Injection Molding Company, a leading manufacturer of injection molding machines, wanted to bring a new machine design to market at a lower price while still meeting strict performance and reliability requirements. The challenge was to size the motors correctly and design a specialized controller that could protect the machine during operation. Maplesoft supported the project with MapleSim and B&R Automation Studio for model-based development.

Maplesoft helped the customer use virtual commissioning to build and validate a physics-based model of the new dual-axis mechanism, test motor loading and motion profiles, and verify controller robustness before physical testing. The simulations identified the precise motor requirements, avoided oversized motors, and confirmed that the controller could maintain axis alignment under varying friction conditions. As a result, the company reduced development risk and costs, shortened testing effort, and was able to launch a more cost-competitive machine without sacrificing reliability.