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ASTUTE 2020 Update September 2020

Here at ASTUTE 2020, we can support your business throughout this period of uncertainty. Our world-class academics and technical experts from across our strong Welsh Universities partnership are available to support you through research and innovation activities. If you wish to discuss opportunities for working with us e.g. to modify your production to develop solutions to support the fight against COVID-19, you can contact us via email.


Image: Investigation of the Warpage Characteristics of Nylon Casing Cap Manufactured by Injection Moulding

Investigation of the Warpage Characteristics of Nylon Casing Cap Manufactured by Injection Moulding

Business: HI-LEX Cable System Co. Ltd.

Expertise: Computational Engineering Modelling Duration: 16 weeks

Location: Neath/Port Talbot


HI-LEX Cable System Co. Ltd. was founded in 2000 and is a producer of electromechanical devices and control cables for the automotive industry. ASTUTE was involved in this project to assist the company to find relationships between the moulding process parameters and a component’s final geometry.


The study focussed on a “Casing Cap” manufactured from glass filled nylon and the project was divided into two work packages. The first focussed on material characterisation while the second part explored the effect of the Injection moulding process settings on part warpage.
DSC was used to measure crystallinity and digital microscopy/image analyses established fibre orientation. To support the experimental studies, Moldflow injection moulding simulations were run to confirm the fibre orientation pattern in relation to the warpage characteristics.


The project concluded that differential fibre orientation had caused an unbalanced shrinkage pattern which resulted in part warpage. By altering the injection location, a more uniform fibre orientation could be attained leading to a reduction of  warpage.

“Quickly understanding the root cause of an issue that we had been working to solve for some time.”

- Kevin Dunster, European Engineering Manager,
HI-LEX Cable System Co. Ltd.

Due to focus on Smart Specialisation, some of the expertise areas in the case studies might not be covered in the current ASTUTE 2020.