Quick Overview
- 1#1: Autodesk Moldflow - Delivers industry-leading injection molding simulation for optimizing part design, tooling, and manufacturing processes with advanced fill, pack, warp, and cool analyses.
- 2#2: Moldex3D - Provides true 3D CAE simulation for injection molding, excelling in fiber-reinforced composites, warpage prediction, and multi-component molding.
- 3#3: SIGMASOFT Virtual Molding - Offers comprehensive process simulation from machine to part, including true 3D cooling channels and machine data integration for realistic molding predictions.
- 4#4: SolidWorks Plastics - Integrates seamless injection molding simulation directly within SolidWorks CAD for rapid design validation and optimization.
- 5#5: CADMOULD - Enables fast 3D and 2.5D simulation of injection molding processes with focus on flow, cooling, and shrinkage for efficient tooling design.
- 6#6: Ansys Polyflow - Simulates complex viscoelastic flows in injection molding and extrusion with high-fidelity rheology models for polymer processing.
- 7#7: Siemens NX Plastics - Integrates advanced molding simulation into NX CAD/CAM environment for fill, pack, warp, and fiber orientation analysis.
- 8#8: REM3D - Performs detailed thermo-mechanical simulation of injection molding processes including residual stresses and springback.
- 9#9: 3DEXPERIENCE Plastics - Cloud-based platform for collaborative injection molding simulation integrated with CATIA and SIMULIA for design-to-manufacturing workflow.
- 10#10: FLOW-3D - CFD-based simulation supporting injection molding with detailed free-surface flow, heat transfer, and solidification modeling.
Tools were selected based on accuracy in simulating critical processes (fill, pack, warp, cooling), ease of integration with CAD/CAM workflows, technical innovation (e.g., composites, multi-component molding), and overall value, ensuring a blend of cutting-edge capability and real-world utility.
Comparison Table
This comparison table examines key injection molding simulation software tools, featuring Autodesk Moldflow, Moldex3D, SIGMASOFT Virtual Molding, SolidWorks Plastics, CADMOULD, and more, to highlight their unique capabilities, accuracy, and suitability for diverse manufacturing scenarios.
| # | Tool | Category | Overall | Features | Ease of Use | Value |
|---|---|---|---|---|---|---|
| 1 | Autodesk Moldflow Delivers industry-leading injection molding simulation for optimizing part design, tooling, and manufacturing processes with advanced fill, pack, warp, and cool analyses. | enterprise | 9.5/10 | 9.8/10 | 8.2/10 | 8.9/10 |
| 2 | Moldex3D Provides true 3D CAE simulation for injection molding, excelling in fiber-reinforced composites, warpage prediction, and multi-component molding. | specialized | 9.2/10 | 9.6/10 | 7.4/10 | 8.7/10 |
| 3 | SIGMASOFT Virtual Molding Offers comprehensive process simulation from machine to part, including true 3D cooling channels and machine data integration for realistic molding predictions. | specialized | 9.0/10 | 9.5/10 | 7.8/10 | 8.5/10 |
| 4 | SolidWorks Plastics Integrates seamless injection molding simulation directly within SolidWorks CAD for rapid design validation and optimization. | enterprise | 8.5/10 | 8.8/10 | 9.0/10 | 7.5/10 |
| 5 | CADMOULD Enables fast 3D and 2.5D simulation of injection molding processes with focus on flow, cooling, and shrinkage for efficient tooling design. | specialized | 8.7/10 | 8.8/10 | 9.2/10 | 8.4/10 |
| 6 | Ansys Polyflow Simulates complex viscoelastic flows in injection molding and extrusion with high-fidelity rheology models for polymer processing. | enterprise | 8.2/10 | 9.1/10 | 6.8/10 | 7.4/10 |
| 7 | Siemens NX Plastics Integrates advanced molding simulation into NX CAD/CAM environment for fill, pack, warp, and fiber orientation analysis. | enterprise | 8.8/10 | 9.3/10 | 7.8/10 | 8.2/10 |
| 8 | REM3D Performs detailed thermo-mechanical simulation of injection molding processes including residual stresses and springback. | specialized | 8.1/10 | 8.7/10 | 7.4/10 | 7.8/10 |
| 9 | 3DEXPERIENCE Plastics Cloud-based platform for collaborative injection molding simulation integrated with CATIA and SIMULIA for design-to-manufacturing workflow. | enterprise | 8.2/10 | 9.0/10 | 7.4/10 | 7.8/10 |
| 10 | FLOW-3D CFD-based simulation supporting injection molding with detailed free-surface flow, heat transfer, and solidification modeling. | specialized | 7.4/10 | 8.2/10 | 6.1/10 | 6.8/10 |
Delivers industry-leading injection molding simulation for optimizing part design, tooling, and manufacturing processes with advanced fill, pack, warp, and cool analyses.
Provides true 3D CAE simulation for injection molding, excelling in fiber-reinforced composites, warpage prediction, and multi-component molding.
Offers comprehensive process simulation from machine to part, including true 3D cooling channels and machine data integration for realistic molding predictions.
Integrates seamless injection molding simulation directly within SolidWorks CAD for rapid design validation and optimization.
Enables fast 3D and 2.5D simulation of injection molding processes with focus on flow, cooling, and shrinkage for efficient tooling design.
Simulates complex viscoelastic flows in injection molding and extrusion with high-fidelity rheology models for polymer processing.
Integrates advanced molding simulation into NX CAD/CAM environment for fill, pack, warp, and fiber orientation analysis.
Performs detailed thermo-mechanical simulation of injection molding processes including residual stresses and springback.
Cloud-based platform for collaborative injection molding simulation integrated with CATIA and SIMULIA for design-to-manufacturing workflow.
CFD-based simulation supporting injection molding with detailed free-surface flow, heat transfer, and solidification modeling.
Autodesk Moldflow
enterpriseDelivers industry-leading injection molding simulation for optimizing part design, tooling, and manufacturing processes with advanced fill, pack, warp, and cool analyses.
True 3D DOE (Design of Experiments) warpage analysis with viscoelastic modeling for hyper-accurate prediction of molded part distortions
Autodesk Moldflow is the industry-leading injection molding simulation software suite from Autodesk, used to predict and optimize plastic injection molding processes. It simulates critical phases including filling, packing, cooling, and warpage, helping users identify defects like short shots, sinks, and distortions before physical prototyping. With advanced 3D and midplane meshing, extensive material databases, and integration with CAD tools like Fusion 360 and Inventor, it supports complex part designs and multi-cavity molds for enhanced manufacturing efficiency.
Pros
- Unmatched simulation accuracy and comprehensive analysis for filling, cooling, warpage, and fiber orientation
- Vast database of over 14,000 validated materials and process-specific advisories
- Seamless integration with Autodesk CAD ecosystem and cloud-based collaboration options
Cons
- Steep learning curve requiring specialized training for full utilization
- High subscription costs prohibitive for small businesses
- Computationally intensive, demanding high-end hardware for complex models
Best For
Enterprise-level engineering teams in plastics manufacturing optimizing complex molds and reducing production iterations.
Pricing
Annual subscription starting at ~$10,000-$25,000 depending on modules (Insight/Adviser/Synergy); custom enterprise quotes required.
Moldex3D
specializedProvides true 3D CAE simulation for injection molding, excelling in fiber-reinforced composites, warpage prediction, and multi-component molding.
Best-in-class fiber orientation and induced warpage prediction for fiber-reinforced thermoplastics
Moldex3D is a leading CAE software for plastic injection molding simulation, providing detailed predictions of the entire molding process including filling, packing, cooling, and warpage. It excels in true 3D analysis, supporting complex scenarios like multi-component molding, fiber-reinforced composites, gas-assisted injection, and overmolding. Used by major OEMs worldwide, it helps engineers optimize designs, reduce defects, and shorten time-to-market.
Pros
- Exceptionally accurate true 3D simulations and meshing
- Comprehensive support for advanced processes like fiber composites and multi-shot molding
- Extensive validated material database with thousands of plastics
Cons
- Steep learning curve requiring specialized training
- High computational demands needing powerful hardware
- Premium pricing limits accessibility for small firms
Best For
Large engineering teams and manufacturers optimizing complex, high-precision injection molded parts in industries like automotive and electronics.
Pricing
Enterprise licensing model; perpetual licenses start at ~$20,000+ with annual maintenance, or subscription from $10,000/year; custom quotes required.
SIGMASOFT Virtual Molding
specializedOffers comprehensive process simulation from machine to part, including true 3D cooling channels and machine data integration for realistic molding predictions.
Process Window Analysis for identifying stable processing parameters across material, machine, and mold variations
SIGMASOFT Virtual Molding is an advanced CAE simulation software specialized in true 3D injection molding analysis for plastics processing. It simulates complex processes like multi-component molding, gas-assist, overmolding, and reactive injection molding to predict defects, optimize cycle times, and ensure part quality. The software integrates extensive material databases and CAD models to enable virtual prototyping and process window determination without physical trials.
Pros
- True 3D simulation engine for accurate cavity-wide analysis without midplane approximations
- Comprehensive Process Window technology for robust DOE and variation analysis
- Extensive validated material database with over 12,000 grades
Cons
- Steep learning curve requiring CAE expertise
- High hardware requirements for complex simulations
- Pricing is premium and not transparent
Best For
Experienced injection molding engineers and R&D teams in OEMs or tier-1 suppliers handling complex, high-volume production molds.
Pricing
Custom enterprise licensing; perpetual licenses start around $15,000-$30,000 per seat plus annual maintenance; modular add-ons available.
SolidWorks Plastics
enterpriseIntegrates seamless injection molding simulation directly within SolidWorks CAD for rapid design validation and optimization.
CAD-embedded workflow with automatic meshing, allowing simulations directly on native SolidWorks geometry without data import/export
SolidWorks Plastics is an integrated simulation tool within the SolidWorks CAD ecosystem designed specifically for injection molding analysis. It simulates key stages including filling, packing, cooling, and warpage to help users optimize plastic part designs and predict manufacturing defects early. The software supports various molding processes like single-cavity, multi-cavity, gas-assist, and insert molding, providing actionable insights without leaving the CAD environment.
Pros
- Seamless integration with SolidWorks CAD for direct model simulation
- Comprehensive analysis of fill, pack, cool, and warp with intuitive wizards
- Accurate predictions using TrueMesh technology for complex geometries
Cons
- Requires a SolidWorks license, limiting accessibility for non-SolidWorks users
- Material database is solid but smaller than dedicated competitors like Moldflow
- High cost as a premium add-on subscription
Best For
Design engineers and teams already using SolidWorks who want embedded injection molding simulation to iterate designs quickly without external tools.
Pricing
Annual subscription add-on to SolidWorks Premium, typically $4,000–$6,000/year depending on edition and region.
CADMOULD
specializedEnables fast 3D and 2.5D simulation of injection molding processes with focus on flow, cooling, and shrinkage for efficient tooling design.
Direct-from-CAD simulation using hybrid FEM/BEM for ultra-fast 3D filling analysis without traditional meshing
CADMOULD by SimpaTec is a specialized injection molding simulation software that predicts process behavior including filling, packing, cooling, and warpage directly from CAD geometry. It employs advanced hybrid FEM/BEM methods for rapid, accurate 3D simulations, enabling optimization of mold design and process parameters early in development. Seamlessly integrated with CAD systems like SolidWorks, NX, and Creo, it reduces iteration times and material waste for plastics engineers.
Pros
- Exceptionally fast simulation times due to hybrid meshless approach
- Native CAD integration for seamless workflow without data import/export
- Strong accuracy in warpage and fiber orientation predictions
Cons
- Smaller material database requiring custom additions
- Limited advanced rheological models compared to top competitors
- Pricing can escalate with additional modules
Best For
Mid-sized engineering teams seeking quick, CAD-embedded simulations for process optimization without deep CAE expertise.
Pricing
Module-based licensing starting at around €4,000-€10,000 annually per seat, with custom quotes for full suites.
Ansys Polyflow
enterpriseSimulates complex viscoelastic flows in injection molding and extrusion with high-fidelity rheology models for polymer processing.
Advanced viscoelastic and fiber orientation models for precise prediction of warpage in fiber-reinforced injection molded parts
Ansys Polyflow is a computational fluid dynamics (CFD) solver specialized in simulating polymer processing operations, including injection molding, extrusion, and blow molding. It accurately models complex viscous flows, non-Newtonian rheologies, fiber orientations, and residual stresses during the filling, packing, and cooling phases of injection molding. Integrated into the Ansys Workbench environment, it enables multiphysics coupling with structural and thermal analyses for comprehensive mold design optimization.
Pros
- Exceptional accuracy for complex rheologies and fiber-filled materials
- Seamless integration with Ansys suite for multiphysics simulations
- Robust handling of free-surface flows and residual stress predictions
Cons
- Steep learning curve due to general CFD workflow
- High computational demands requiring powerful hardware
- Less intuitive interface compared to dedicated molding software
Best For
Experienced engineering teams in large enterprises needing advanced polymer flow simulations integrated with broader Ansys multiphysics workflows.
Pricing
Enterprise subscription licensing, typically $20,000+ annually per seat; custom quotes required via Ansys sales.
Siemens NX Plastics
enterpriseIntegrates advanced molding simulation into NX CAD/CAM environment for fill, pack, warp, and fiber orientation analysis.
Fully associative 3D simulation that automatically updates with parametric CAD design changes
Siemens NX Plastics is a comprehensive injection molding simulation module integrated into the Siemens NX CAD/CAM/CAE platform, enabling users to predict and optimize the entire molding process from fill, pack, and cool to warp analysis directly on 3D models. It supports advanced simulations for complex geometries, fiber-reinforced materials, and overmolding, providing high-fidelity results validated against physical trials. The tool's associative nature ensures simulations update automatically with design changes, streamlining iteration in product development.
Pros
- Seamless integration with NX CAD for associative, parametric simulations
- Advanced 3D analysis including fiber orientation, warpage, and gas-assist
- High accuracy with proven validation against real-world molding trials
Cons
- Steep learning curve due to NX platform complexity
- High cost with enterprise-level licensing
- Resource-intensive, requiring powerful hardware for large models
Best For
Large engineering teams in manufacturing firms handling complex, high-precision plastic parts that need integrated CAD-simulation workflows.
Pricing
Subscription-based enterprise licensing; typically $10,000-$25,000+ per seat annually, with Plastics module as add-on—contact Siemens for custom quotes.
REM3D
specializedPerforms detailed thermo-mechanical simulation of injection molding processes including residual stresses and springback.
Automatic 3D remeshing technology that dynamically adapts the mesh during simulation for precise tracking of material flow in intricate geometries.
REM3D by Transvalor is a specialized 3D simulation software for injection molding of thermoplastics, thermosets, and rubber, modeling the full process from filling and packing to cooling, warpage, and residual stresses. It excels in handling complex geometries, multi-material injections, and advanced phenomena like gas-assisted or reactive molding. Engineers use it to optimize mold designs, predict defects, and reduce physical trials in production workflows.
Pros
- High-accuracy 3D simulations with dynamic remeshing for complex parts
- Comprehensive support for fiber-filled, reactive, and multi-shot molding
- Strong prediction of warpage, shrinkage, and weld lines
Cons
- Steep learning curve and less intuitive interface
- High hardware demands for large simulations
- Pricing and support geared toward enterprise users only
Best For
Experienced CAE engineers and R&D teams in high-precision plastics manufacturing needing advanced 3D molding analysis.
Pricing
Enterprise licensing model with custom quotes; typically €20,000–€60,000 annually depending on modules and support.
3DEXPERIENCE Plastics
enterpriseCloud-based platform for collaborative injection molding simulation integrated with CATIA and SIMULIA for design-to-manufacturing workflow.
Real-time collaborative simulation environment integrated across design, simulation, and manufacturing on the 3DEXPERIENCE cloud platform
3DEXPERIENCE Plastics is a cloud-based simulation software from Dassault Systèmes, designed for advanced injection molding analysis within the 3DEXPERIENCE platform. It simulates key processes like filling, packing, cooling, and warpage, supporting complex materials such as fiber-reinforced plastics and multi-shot molding. Engineers can predict defects, optimize designs, and collaborate in real-time across teams.
Pros
- Advanced simulation capabilities including fiber orientation and overmolding
- Seamless integration with CATIA and the 3DEXPERIENCE platform for end-to-end workflows
- Cloud-based collaboration enabling real-time team simulations
Cons
- Steep learning curve due to the comprehensive platform interface
- High cost suitable mainly for enterprises
- Performance dependent on cloud resources or high-end hardware
Best For
Large engineering teams in enterprises already using Dassault Systèmes tools who need integrated, collaborative injection molding simulations.
Pricing
Enterprise subscription-based; typically $10,000+ per user/year, with custom quotes based on roles and platform access.
FLOW-3D
specializedCFD-based simulation supporting injection molding with detailed free-surface flow, heat transfer, and solidification modeling.
Patented TruVOF volume tracking for unmatched accuracy in simulating dynamic mold filling and air entrapment
FLOW-3D is a powerful computational fluid dynamics (CFD) software renowned for simulating complex free-surface flows, with specific capabilities for injection molding processes including cavity filling, packing, cooling, and warpage prediction. It excels in modeling non-Newtonian polymer melts, gas-assisted injection, and multi-component flows using its advanced volume-of-fluid (VOF) method. While versatile across industries like casting and forming, its injection molding simulations provide high-fidelity results for defect prediction but require expertise in CFD setup.
Pros
- Superior free-surface tracking with TruVOF for accurate fill pattern predictions
- Robust multi-physics coupling including heat transfer, solidification, and stresses
- Extensive library of rheological models for polymers and composites
Cons
- Steep learning curve due to general CFD complexity not tailored solely to molding
- Longer computation times compared to specialized IM software
- High cost with custom licensing not ideal for small teams
Best For
Advanced engineering teams in R&D requiring detailed CFD analysis for complex injection molding challenges like gas-assist or reactive resins.
Pricing
Perpetual licenses start around $20,000+ with annual maintenance fees of 15-20%; custom quotes for modules.
Conclusion
The top 3 software tools set a new standard, with Autodesk Moldflow leading as the top choice, delivering industry-leading capabilities for optimizing part design, tooling, and manufacturing processes. Moldex3D and SIGMASOFT Virtual Molding follow, each excelling in distinct areas like composites and multi-component molding, or process integration from machine to part, respectively.
Begin your journey toward enhanced molding efficiency by trying Autodesk Moldflow, the top-ranked solution for rapid design validation and process optimization.
Tools Reviewed
All tools were independently evaluated for this comparison