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Simulation is Not Just a Tool, but a Strategy: How Hirschmann Automotive Masters Complex Processes with Moldex3D

In the time-critical automotive manufacturing industry, how do you strike a balance between “extreme precision” and “mass production speed”? Austrian leader Hirschmann Automotive provides the answer. For them, simulation analysis has long transcended simple “troubleshooting”—it is a core strategy for enhancing product competitiveness.

The Key to Victory: Precisely Mastering “Overmolding”

Hirschmann’s flagship products—such as connectors, sensors, and wiring harness systems—rely heavily on multi-component and electromechanical integrated designs. The most difficult challenge for these products is Overmolding.

Katzen Sascha, Team Leader of Moldflow Simulation, points out that this is not just simple plastic injection, but involves the precise combination of metal and electronic components. Moldex3D’s high-precision prediction capabilities in the overmolding process became Hirschmann’s winning point:

• Solving Complexity: Accurately predicting potential risks at multi-material interfaces (such as burn marks or wire sweep).
• Supporting Full Automation: Ensuring designs are optimized before entering fully automated production lines, achieving the goal of “Zero Trial and Error.”

Internalized as a DFM Standard, Ensuring Compliance and Traceability

Now, mold flow analysis is fully integrated into Hirschmann’s DFM (Design for Manufacturing) process, becoming a daily standard for engineers. This not only significantly reduces mold modification costs but also brings two major advantages to quality management:

• Meeting Automotive Standards: Becoming a key link in complying with the IATF 16949 quality management system.
• Complete Traceability: Simulation data is fully archived, serving as a solid foundation for PPAP (Production Part Approval Process) submissions and handling process audits.
  

Simulation should not just be a tool for troubleshooting; it is a strategic investment in design quality, process efficiency, and cost control.

— Katzian Sascha, Team Leader Moldflow Simulation, Hirschmann Automotive

Looking Ahead: The Fusion of AI and Real-World Data

Hirschmann’s pace of digitalization has not stopped. Looking ahead, they plan to further combine AI-driven optimization with real production data, utilizing Moldex3D to continuously shorten Time-to-Market and maintain a lead on the path of digital transformation.