Quick Overview
- 1#1: Autodesk Moldflow - Delivers industry-leading simulation for plastic injection molding, analyzing fill, pack, cool, warp, and fiber orientation to optimize designs.
- 2#2: Moldex3D - Provides true 3D CAE analysis for advanced injection molding simulations including multi-component, fiber-filled materials, and warpage prediction.
- 3#3: SIGMASOFT Virtual Molding - Offers process-oriented virtual molding simulations incorporating real machine data, material behaviors, and hot runner effects for production optimization.
- 4#4: SOLIDWORKS Plastics - Integrates plastic injection molding simulation seamlessly within SOLIDWORKS CAD for fill, pack, cool, and warp analysis on digital prototypes.
- 5#5: Cadmould 3D-F - Enables fast 3D finite element simulations for injection molding to quickly assess flow, cooling, and warpage during early design stages.
- 6#6: NX Plastics - Performs comprehensive plastics flow simulation integrated into NX CAD/CAM for mold design, cooling channels, and process optimization.
- 7#7: Creo Plastics - Supports injection molding analysis within PTC Creo CAD, simulating fill patterns, pressure distribution, and cooling times for part validation.
- 8#8: Altair Inspire Mold - Combines topology optimization with injection molding simulation to design lightweight polymer parts and predict manufacturing defects.
- 9#9: Ansys Polyflow - Simulates complex viscous flows in polymer processing, including injection molding rheology, die swell, and fiber orientation.
- 10#10: COMSOL Multiphysics - Enables customizable multiphysics simulations of plastic injection molding flows, heat transfer, and structural mechanics via the Polymer Flow Module.
These tools were selected based on their ability to deliver accurate process simulation (including fill, pack, cool, and warp), integration with workflows, user experience, and value in balancing performance and practicality for diverse manufacturing needs.
Comparison Table
Plastic injection molding simulation software is vital for streamlining production processes, minimizing defects, and enhancing part performance, with tools like Autodesk Moldflow, Moldex3D, SIGMASOFT Virtual Molding, SOLIDWORKS Plastics, and Cadmould 3D-F offering distinct approaches. This comparison table outlines key features, simulation accuracy, and application suitability of these solutions, helping readers determine the ideal software for their specific molding needs, whether for prototyping, optimization, or large-scale manufacturing.
| # | Tool | Category | Overall | Features | Ease of Use | Value |
|---|---|---|---|---|---|---|
| 1 | Autodesk Moldflow Delivers industry-leading simulation for plastic injection molding, analyzing fill, pack, cool, warp, and fiber orientation to optimize designs. | enterprise | 9.6/10 | 9.8/10 | 8.4/10 | 9.2/10 |
| 2 | Moldex3D Provides true 3D CAE analysis for advanced injection molding simulations including multi-component, fiber-filled materials, and warpage prediction. | specialized | 9.4/10 | 9.7/10 | 8.3/10 | 8.6/10 |
| 3 | SIGMASOFT Virtual Molding Offers process-oriented virtual molding simulations incorporating real machine data, material behaviors, and hot runner effects for production optimization. | specialized | 8.7/10 | 9.3/10 | 7.4/10 | 8.1/10 |
| 4 | SOLIDWORKS Plastics Integrates plastic injection molding simulation seamlessly within SOLIDWORKS CAD for fill, pack, cool, and warp analysis on digital prototypes. | enterprise | 8.6/10 | 9.0/10 | 8.7/10 | 7.8/10 |
| 5 | Cadmould 3D-F Enables fast 3D finite element simulations for injection molding to quickly assess flow, cooling, and warpage during early design stages. | specialized | 8.4/10 | 8.6/10 | 9.0/10 | 8.0/10 |
| 6 | NX Plastics Performs comprehensive plastics flow simulation integrated into NX CAD/CAM for mold design, cooling channels, and process optimization. | enterprise | 8.4/10 | 9.2/10 | 7.1/10 | 7.8/10 |
| 7 | Creo Plastics Supports injection molding analysis within PTC Creo CAD, simulating fill patterns, pressure distribution, and cooling times for part validation. | enterprise | 7.9/10 | 8.4/10 | 7.1/10 | 7.4/10 |
| 8 | Altair Inspire Mold Combines topology optimization with injection molding simulation to design lightweight polymer parts and predict manufacturing defects. | specialized | 8.4/10 | 8.7/10 | 8.1/10 | 8.0/10 |
| 9 | Ansys Polyflow Simulates complex viscous flows in polymer processing, including injection molding rheology, die swell, and fiber orientation. | enterprise | 7.6/10 | 8.4/10 | 6.5/10 | 7.1/10 |
| 10 | COMSOL Multiphysics Enables customizable multiphysics simulations of plastic injection molding flows, heat transfer, and structural mechanics via the Polymer Flow Module. | enterprise | 7.2/10 | 8.5/10 | 5.2/10 | 6.0/10 |
Delivers industry-leading simulation for plastic injection molding, analyzing fill, pack, cool, warp, and fiber orientation to optimize designs.
Provides true 3D CAE analysis for advanced injection molding simulations including multi-component, fiber-filled materials, and warpage prediction.
Offers process-oriented virtual molding simulations incorporating real machine data, material behaviors, and hot runner effects for production optimization.
Integrates plastic injection molding simulation seamlessly within SOLIDWORKS CAD for fill, pack, cool, and warp analysis on digital prototypes.
Enables fast 3D finite element simulations for injection molding to quickly assess flow, cooling, and warpage during early design stages.
Performs comprehensive plastics flow simulation integrated into NX CAD/CAM for mold design, cooling channels, and process optimization.
Supports injection molding analysis within PTC Creo CAD, simulating fill patterns, pressure distribution, and cooling times for part validation.
Combines topology optimization with injection molding simulation to design lightweight polymer parts and predict manufacturing defects.
Simulates complex viscous flows in polymer processing, including injection molding rheology, die swell, and fiber orientation.
Enables customizable multiphysics simulations of plastic injection molding flows, heat transfer, and structural mechanics via the Polymer Flow Module.
Autodesk Moldflow
enterpriseDelivers industry-leading simulation for plastic injection molding, analyzing fill, pack, cool, warp, and fiber orientation to optimize designs.
Fusion analysis combining fill, pack, cool, and warp in a single, highly accurate simulation run for holistic process optimization
Autodesk Moldflow is the industry-leading simulation software for plastic injection molding, providing comprehensive analysis of the entire molding process including filling, packing, cooling, and warping to predict and prevent manufacturing defects. It supports advanced features like fiber-reinforced materials simulation, overmolding, and gas-assist molding, enabling precise optimization of part designs, molds, and processes. With seamless integration into the Autodesk ecosystem and cloud-based options via Moldflow Insight, it accelerates time-to-market for high-volume production.
Pros
- Exceptionally accurate and validated simulations backed by decades of industry data
- Broadest range of analysis types including advanced topics like reactive molding and warpage prediction
- Strong CAD integration and automation tools for efficient workflows
Cons
- Steep learning curve for non-experts due to complex meshing and setup
- High subscription costs prohibitive for small teams
- Resource-intensive requiring powerful hardware for large models
Best For
Professional mold designers, injection molding engineers, and manufacturers seeking top-tier accuracy to optimize high-volume production parts.
Pricing
Subscription-based, typically $15,000–$25,000 per year per license depending on edition (Synergy, Premium, Ultimate); volume discounts available.
Moldex3D
specializedProvides true 3D CAE analysis for advanced injection molding simulations including multi-component, fiber-filled materials, and warpage prediction.
Advanced viscoelastic warpage analysis with hybrid modeling for unmatched prediction accuracy in thin-walled and fiber-filled parts
Moldex3D is a leading CAE software for plastic injection molding simulation, providing comprehensive analysis of the entire process including filling, packing, cooling, and warping to optimize designs and reduce defects. It excels in advanced simulations like fiber-reinforced composites, multi-component molding, gas-assist, and overmolding, supported by a vast material database and seamless CAD integration. The software helps manufacturers minimize trial molds, shorten development cycles, and improve part quality through accurate predictions of issues like weld lines, air traps, and residual stresses.
Pros
- Superior accuracy in warpage and fiber orientation predictions
- Extensive support for complex processes like insert overmolding and rubber injection
- Robust automation tools and CAD/PLM integration for efficient workflows
Cons
- High system resource demands for large models
- Steep learning curve despite improved GUI
- Enterprise pricing limits accessibility for small firms
Best For
Experienced injection molding engineers and design teams in automotive, electronics, and consumer goods industries needing precise simulations for high-volume production.
Pricing
Enterprise licensing with perpetual or annual subscriptions starting at around $10,000+ per seat; custom quotes required for modules and support.
SIGMASOFT Virtual Molding
specializedOffers process-oriented virtual molding simulations incorporating real machine data, material behaviors, and hot runner effects for production optimization.
True 3D microscopic simulation of filled materials and machine-specific process fluctuations for unparalleled production realism
SIGMASOFT Virtual Molding is an advanced 3D simulation software for plastic injection molding that replicates the entire production process, from filling and packing to cooling and warpage prediction under real-world machine conditions. It excels in modeling complex phenomena like fiber orientation, residual stresses, and multi-component molding, supported by a vast material database including filled compounds. The tool enables virtual DOE to optimize process windows and reduce physical trials, making it ideal for high-precision manufacturing.
Pros
- Exceptionally accurate process simulations including machine behavior and material microstructure
- Comprehensive support for advanced processes like overmolding, gas-assist, and hybrid molding
- Extensive validated material library with filler content modeling
Cons
- Steep learning curve requiring CAE expertise
- High computational demands needing powerful hardware
- Pricing is premium and quote-based, less accessible for small firms
Best For
Large-scale manufacturers and engineering teams optimizing complex, high-volume injection molding processes to minimize defects and trials.
Pricing
Custom quote-based licensing, typically $25,000+ annually per seat with maintenance; modular options available.
SOLIDWORKS Plastics
enterpriseIntegrates plastic injection molding simulation seamlessly within SOLIDWORKS CAD for fill, pack, cool, and warp analysis on digital prototypes.
True in-CAD integration allowing real-time design modifications and immediate re-simulation without data export
SOLIDWORKS Plastics is an integrated simulation tool within the SOLIDWORKS CAD ecosystem, specialized for plastic injection molding analysis. It simulates the entire molding process—including fill, pack, cool, and warp—to predict defects like warpage, sink marks, short shots, and weld lines. Users can optimize part geometry, runner systems, gate locations, and cooling channels directly from their 3D CAD models, reducing the need for physical prototypes and iterations.
Pros
- Seamless integration with SOLIDWORKS CAD for in-context editing and simulation
- Comprehensive multi-stage analysis (fill, pack, cool, warp) with accurate material databases
- Wizard-driven setup simplifies complex simulations for faster results
Cons
- Requires a SOLIDWORKS license, limiting standalone use
- High cost, especially for small teams or non-enterprise users
- Advanced fiber-reinforced material simulations can be computationally intensive
Best For
CAD engineers and product designers already using SOLIDWORKS who want embedded injection molding simulation to optimize designs early.
Pricing
Annual subscription as an add-on to SOLIDWORKS; Professional ~$4,500/year, Premium ~$9,000/year (bundled with CAD licensing).
Cadmould 3D-F
specializedEnables fast 3D finite element simulations for injection molding to quickly assess flow, cooling, and warpage during early design stages.
3D-F simulation kernel for true 3D flow analysis with surface meshes, enabling simulations up to 100x faster than traditional FEM methods
Cadmould 3D-F by Simcon is a advanced simulation software for plastic injection molding, utilizing its proprietary 3D-F (3D-Flow) technology to deliver fast and accurate predictions of filling, packing, cooling, and warpage using surface meshes rather than full volumetric models. This approach significantly reduces computation times while maintaining high fidelity for thin-walled and complex geometries. It supports material databases, process optimization, and design iterations, making it ideal for early-stage development in injection molding projects.
Pros
- Exceptionally fast simulation times due to 3D-F shell mesh technology
- Highly accurate warpage and shrinkage predictions
- Intuitive user interface with straightforward workflow
Cons
- Limited to surface-based meshing, less ideal for very thick parts
- Smaller material database compared to top competitors like Autodesk Moldflow
- Advanced multi-component and gas-assist simulations require additional modules
Best For
Design engineers and mold makers who need quick, reliable simulations for iterative optimization in the early stages of thin-walled plastic part development.
Pricing
Quote-based pricing; perpetual licenses or annual subscriptions typically start around €10,000-€20,000 depending on modules and user seats.
NX Plastics
enterprisePerforms comprehensive plastics flow simulation integrated into NX CAD/CAM for mold design, cooling channels, and process optimization.
Fully associative simulation linked to parametric CAD geometry for real-time design changes and automatic mesh updates
NX Plastics, part of the Siemens NX software suite, is a comprehensive CAE tool for simulating plastic injection molding processes, including fill, pack, cool, warp, and overmolding analyses. It integrates directly with NX CAD/CAM/CAE environments, enabling seamless design validation, optimization, and mold creation without data translation. Advanced capabilities cover fiber-reinforced materials, viscoelastic flow, and multi-component molding, helping predict defects like weld lines, sink marks, and warpage.
Pros
- Deep integration with Siemens NX CAD/CAM for associative simulations and automated mold design
- Advanced physics modeling for complex materials like fiber-filled plastics and gas-assist processes
- High accuracy in warpage prediction and optimization tools to reduce iterations
Cons
- Steep learning curve due to the complexity of the full NX platform
- High cost and resource-intensive, requiring powerful hardware
- Limited standalone use; best within Siemens ecosystem
Best For
Enterprise-level manufacturers using Siemens NX who need end-to-end integrated mold design, simulation, and production planning.
Pricing
Included as an add-on to Siemens NX subscriptions; annual licensing starts around $15,000-$25,000 per seat depending on modules, with perpetual options available.
Creo Plastics
enterpriseSupports injection molding analysis within PTC Creo CAD, simulating fill patterns, pressure distribution, and cooling times for part validation.
Unified CAD-to-simulation environment with automatic design updates from analysis results
Creo Plastics, part of PTC's Creo Parametric suite, is a comprehensive tool for plastic part design, mold creation, and injection molding simulation. It provides advanced analyses including fill, pack, cool, warp, and overmolding to predict and optimize manufacturing outcomes. Seamlessly integrated with CAD modeling, it enables iterative design adjustments directly from simulation results, reducing time to production.
Pros
- Seamless integration with Creo CAD for unified design-simulation workflow
- Robust simulation capabilities covering fill, pack, warp, cooling, and fiber analysis
- Advanced tools for automated mold design, runner balancing, and parting line creation
Cons
- Steep learning curve due to Creo's complex interface, especially for simulation novices
- High cost as an add-on module to expensive Creo licensing
- Less specialized depth in advanced meshing or multi-cavity analysis compared to dedicated tools like Moldflow
Best For
CAD designers and engineers in manufacturing firms already using PTC Creo who need integrated plastics simulation without switching software.
Pricing
Subscription-based via Creo Parametric (base ~$2,800-$5,000/user/year); Plastics module adds $1,500-$3,000/year—contact PTC for exact quotes.
Altair Inspire Mold
specializedCombines topology optimization with injection molding simulation to design lightweight polymer parts and predict manufacturing defects.
Automatic 3D conformal cooling channel design and optimization for superior heat management
Altair Inspire Mold is a powerful simulation tool within the Altair Inspire suite, designed specifically for plastic injection molding analysis. It enables users to simulate filling, packing, cooling, and warpage phases to predict defects like short shots, weld lines, and sink marks. By integrating seamlessly with CAD geometry and topology optimization, it supports rapid design iterations and mold optimization early in the product development process.
Pros
- Fast simulation times thanks to Altair's efficient solvers and polyhedral meshing
- Seamless integration with CAD and Altair's generative design tools
- Comprehensive defect prediction including fiber orientation for advanced materials
Cons
- Learning curve for users new to the Altair ecosystem
- Limited standalone accessibility without broader Altair licensing
- Fewer specialized molding features compared to dedicated tools like Autodesk Moldflow
Best For
Engineering teams in mid-to-large organizations already using Altair software who need integrated injection molding simulation for optimized product designs.
Pricing
Enterprise subscription-based licensing through Altair Units system; contact sales for custom quotes starting around $10,000+ annually depending on usage.
Ansys Polyflow
enterpriseSimulates complex viscous flows in polymer processing, including injection molding rheology, die swell, and fiber orientation.
Advanced viscoelastic and generalized Newtonian fluid models for highly accurate prediction of die swell and flow-induced stresses
Ansys Polyflow is a specialized CFD simulation software from Ansys designed for polymer processing, including plastic injection molding, extrusion, and blow molding. It accurately models complex non-Newtonian rheologies, viscoelastic behaviors, and multiphysics interactions like heat transfer and fiber orientations during the molding process. While powerful for advanced users, it focuses more on fluid flow dynamics than full-cycle molding analysis like warpage prediction.
Pros
- Exceptional accuracy in simulating non-Newtonian and viscoelastic polymer flows
- Strong multiphysics integration with other Ansys tools for comprehensive analysis
- Handles complex geometries and transient processes effectively
Cons
- Steep learning curve due to general CFD interface not tailored specifically for molding
- Lacks some dedicated molding-specific features like automated warpage or DOE tools found in competitors
- High enterprise-level pricing limits accessibility for smaller teams
Best For
Experienced engineers and R&D teams in polymer industries needing precise rheological simulations for injection molding optimization.
Pricing
Enterprise subscription licensing; typically starts at $10,000+ annually per seat, customized via Ansys sales contact.
COMSOL Multiphysics
enterpriseEnables customizable multiphysics simulations of plastic injection molding flows, heat transfer, and structural mechanics via the Polymer Flow Module.
Seamless integration of injection molding flow with any other physics domain in a single environment
COMSOL Multiphysics is a general-purpose finite element analysis software with a Polymer Processing Module tailored for plastic injection molding simulations, enabling modeling of filling, packing, cooling, and warpage. It excels in coupling molding flow with multiphysics phenomena like heat transfer, structural mechanics, and fiber orientation for comprehensive process analysis. While highly flexible for complex, custom simulations, it requires significant setup compared to dedicated molding tools.
Pros
- Exceptional multiphysics coupling for accurate warpage and residual stress predictions
- Highly customizable interfaces for advanced material models and geometries
- Robust solver for non-isothermal, viscoelastic flows
Cons
- Steep learning curve due to general-purpose interface
- Expensive licensing with high computational demands
- Less streamlined workflows than specialized injection molding software
Best For
Advanced engineers in R&D requiring multiphysics integration for complex injection molding scenarios beyond standard flow analysis.
Pricing
Annual subscriptions start at ~$10,000+ USD for base license plus modules; custom quotes required for full Polymer Processing setup.
Conclusion
The top tools reviewed deliver diverse strengths, with Autodesk Moldflow leading as the top choice, offering industry-leading analysis across fill, pack, and warp. Moldex3D follows, excelling in advanced 3D simulations for multi-component and fiber-filled materials, while SIGMASOFT Virtual Molding impresses with process-oriented insights integrating real machine data. These solutions cater to varied needs, ensuring robust plastic injection molding outcomes whether for design optimization or production validation.
Start with Autodesk Moldflow to boost your mold design efficiency and part quality—explore its capabilities today to elevate your plastic injection molding process.
Tools Reviewed
All tools were independently evaluated for this comparison