Case Study: Formaplex Limited achieves rapid cost recovery and optimized injection‑moulding with Vero Software's VISI Flow

VISI Flow is Vital for Formaplex Mould Tool Integrity

Formaplex is a UK tool and mouldings manufacturer that designs and builds aluminium and steel injection mould tools and low-volume moulded components for automotive, motorsport and aerospace clients. With over 40 CNC machines, 11 injection presses and more than 400 pre‑proven tools produced annually, the company needed a reliable way to ensure mould integrity, prevent damage from incorrect filling or excessive pressure, and validate manufacturability early in the design process.

By adopting VISI Flow from Vero Software, Formaplex ran detailed injection simulations and DFM checks to pinpoint optimal gate locations, balanced runner systems and potential issues such as weld lines or air traps before tool trials. The integrated solution streamlined tool design, CAM and fixture work, improved moulding conditions and avoided costly downtime and repairs — delivering payback within the first month through reduced rework, setup time and material waste.

Formaplex Limited

Adrian Chapman

Technical Director