Case Study: Dudley Associates achieves precise, rework-free injection moulds with Vero Software's VISI Flow

Dudley Associates VISI Flow Removes Guesswork From Mould Manufacture

Dudley Associates, a Leicestershire specialist in high‑grade aluminium tooling and plastic injection mouldings, was tasked with producing a critically accurate polyurethane cover for a water‑powered rock drill used deep underground. The part’s flatness, weld‑line strength and warpage tolerance were paramount—any distortion would bind the drive gear—and discovering moulding problems only at trial would mean costly rework and delays.

Using VISI Flow’s preventative analysis (including a 7,500‑grade polymer database), Dudley validated part geometry, optimized gating, and simulated fill, holding, cooling and shape behaviour to detect warpage, weld lines, air traps and hot spots before tool production. The result: confident commissioning of a high‑precision aluminium mould, elimination of trial‑and‑error rework, faster problem resolution (including post‑production analysis), and reliable production of robust covers on their Engel Victory 300‑tonne machine.

Dudley Associates

Kevin Steele

Design Engineer