Injection Molding

We model the mold filling process for thermoplastics and thermosets non-isothermal, transient and three-dimensional. The simulation model corresponds to the cavity in the real process. Screw chamber, plastication unit and temperature control are included as initial/boundary conditions. Process parameters such as filling rate, switchover point, material and mold temperature can be adopted. The material is simulated non-Newtonian and, in the case of fiber reinforcement, anisotropic.  Key results are temperature and pressure distribution, fiber orientation and statements about weld lines, air inclusions, etc. The fiber orientation created in the process can be used for structure and warpage simulations.

Research focus
  • Non-Newtonian Flow Modelling
  • Anisotropic Flow
  • Fiber Breakage
  • Warpage
  • Recycling Materials
  • Close to contour tempering
  • Probabilistic Simulations


Research projects

Dr.-Ing. Florian Wittemann
Tel.: +49 721 608-45379
Email: florian.wittemann∂


M.Sc. Bhimesh
Tel.: +49 721 608-45895
Email: bhimesh.bhimesh∂


M.Sc. Stjepan Salatovic
Tel.: +49 152 32796259
Email: stjepan.salatovic∂

Process simulation of fiber-reinforced injection molding
Injection molding simulation

Selected publications in the research field

Numerical Study on Uncertainty Effects in Injection Molding
Wittemann, F.; Kärger, L.
2023. 23rd International Conference on Composite Materials : (ICCM 23) held in Belfast, Northern Ireland, from July 30th to August 4th 2023, Queen’s University Belfast
Structural health monitoring in additive manufactured structures by total electrical resistance measurements as
Liebig, W.; Muth, M.; Seitz, M.; Wittemann, F.; Weiss, P.
2022. ECCM20 - Proceedings of the 20th European Conference on Composite Materials - Composites Meet Sustainability (Vol 1-6), Ed.: A. Vassilopoulos, 1110–1117, École Polytechnique Fédérale de Lausanne (EPFL)
Fiber breakage modeling based on hydrodynamic forces in macroscopic process simulations
Wittemann, F.; Maertens, R.; Henning, F.; Kärger, L.
2022. Composites Meet Sustainability - Proceedings of the 20th European Conference on Composite Materials. Ed.: A. Vassilopoulos, École Polytechnique Fédérale de Lausanne (EPFL)
Influence of fiber breakage on flow behavior in fiber length- and orientation-dependent injection molding simulations
Wittemann, F.; Kärger, L.; Henning, F.
2022. Journal of Non-Newtonian Fluid Mechanics, 310, 104950. doi:10.1016/j.jnnfm.2022.104950
Design Approach for a Novel Multi Material Variable Flux Synchronous Reluctance Machine without Rare Earth Magnets
Kesten, J.; Frölich, F.; Wittemann, F.; Knirsch, J.; Bechler, F.; Kärger, L.; Eberhard, P.; Henning, F.; Doppelbauer, M.
2022. 2022 International Conference on Electrical Machines (ICEM), Valencia, Spain, 05-08 September 2022, 2304–2310, Institute of Electrical and Electronics Engineers (IEEE). doi:10.1109/ICEM51905.2022.9910780
Simplified modeling of electromagnets for dynamic simulation of transient effects for a synchronous electric motor
Bechler, F.; Kesten, J.; Wittemann, F.; Henning, F.; Doppelbauer, M.; Eberhard, P.
2021. International Journal of Mechanical System Dynamics, 1 (1), 89–95. doi:10.1002/msd2.12005
Fiber-dependent injection molding simulation of discontinuous reinforced polymers. PhD dissertation
Wittemann, F.
2022, February 16. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000142956
Simulation of Reinforced Reactive Injection Molding with the Finite Volume Method
Wittemann, F.; Maertens, R.; Bernath, A.; Hohberg, M.; Kärger, L.; Henning, F.
2018. Journal of composites science, 2 (1), Aritcle no: 5. doi:10.3390/jcs2010005