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 |
Contact
Dr.-Ing. Florian Wittemann
M.Sc. Christina Dohmen
M.Sc. Stjepan Salatovic
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Selected publications in the research field
Micro-scale flow simulations for determination of interaction coefficients in macroscopic fibre orientation modelling
Wittemann, F.; Hof, L.; Meyer, N.; Kärger, L.
2025, April 9. 14th International Conference on Manufacturing of Advanced Composites (ICMAC 2025), Coventry, United Kingdom, April 9–10, 2025
Wittemann, F.; Hof, L.; Meyer, N.; Kärger, L.
2025, April 9. 14th International Conference on Manufacturing of Advanced Composites (ICMAC 2025), Coventry, United Kingdom, April 9–10, 2025
Injection moulding simulation using a CEL approach: sensitivity analysis for the equation of state and mass scaling
Dohmen, C.; Wittemann, F.; Kärger, L.
2025, April 9. 14th International Conference on Manufacturing of Advanced Composites (ICMAC 2025), Coventry, United Kingdom, April 9–10, 2025
Dohmen, C.; Wittemann, F.; Kärger, L.
2025, April 9. 14th International Conference on Manufacturing of Advanced Composites (ICMAC 2025), Coventry, United Kingdom, April 9–10, 2025
A submodeling approach for efficient prediction of local temperature profiles in component-scale additive manufacturing
Frölich, F.; Hof, L.; Zimmerling, C.; Wittemann, F.; Kärger, L.
2024. The International Journal of Advanced Manufacturing Technology. doi:10.1007/s00170-024-14913-w
Frölich, F.; Hof, L.; Zimmerling, C.; Wittemann, F.; Kärger, L.
2024. The International Journal of Advanced Manufacturing Technology. doi:10.1007/s00170-024-14913-w
Efficient Approximation of Varying Fiber Orientation States in Injection Molded Parts Under Consideration of Multiple Manufacturing Uncertainties
Wittemann, F.; Krauß, C.; Kärger, L.
2025. Applied Composite Materials, 32 (1), 149–172. doi:10.1007/s10443-024-10268-3
Wittemann, F.; Krauß, C.; Kärger, L.
2025. Applied Composite Materials, 32 (1), 149–172. doi:10.1007/s10443-024-10268-3
Modeling Approach for Reactive Injection Molding of Polydisperse Suspensions with Recycled Thermoset Composites
Jetty, B.; Wittemann, F.; Kärger, L.
2024. Polymers, 16 (16), Art.-Nr.: 2245. doi:10.3390/polym16162245
Jetty, B.; Wittemann, F.; Kärger, L.
2024. Polymers, 16 (16), Art.-Nr.: 2245. doi:10.3390/polym16162245
Anisotropic Warpage Prediction of Injection Molded Parts with Phenolic Matrix
Wittemann, F.; Bernath, A.; Meyer, N.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials (ECCM 2024). Ed.: C. Binetruy. Vol. 5, 139–145, European Society for Composite Materials (ESCM)
Wittemann, F.; Bernath, A.; Meyer, N.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials (ECCM 2024). Ed.: C. Binetruy. Vol. 5, 139–145, European Society for Composite Materials (ESCM)
Investigation of the thermoviscoelastic behavior of a closed-cell polymer structural foam under pressure for processing in hybrid LCM processes
Dietrich, S.; Dohmen, C.; Frölich, F.; Jackstadt, A.; Wittemann, F.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials. Vol 2 Material Science. Ed.: C. Binetruy, 548–554, European Society for Composite Materials (ESCM)
Dietrich, S.; Dohmen, C.; Frölich, F.; Jackstadt, A.; Wittemann, F.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials. Vol 2 Material Science. Ed.: C. Binetruy, 548–554, European Society for Composite Materials (ESCM)
of-rtm-6 – An OpenFOAM-6 extension with curing models and anisotropic permeability for usage in LCM simulations
Bernath, A.; Seuffert, J.; Dietrich, S.; Poppe, N.; Magagnato, D.; Wittemann, F.; Henning, F.; Kärger, L.
2024. doi:10.5281/zenodo.13327698
Bernath, A.; Seuffert, J.; Dietrich, S.; Poppe, N.; Magagnato, D.; Wittemann, F.; Henning, F.; Kärger, L.
2024. doi:10.5281/zenodo.13327698
Initial stack placement strategies for carbon fiber- reinforced sheet molding compound (C-SMC)
Olma, M.; Meyer, N.; Krauß, C.; Wittemann, F.; Kärger, L.
2024, July 5. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Olma, M.; Meyer, N.; Krauß, C.; Wittemann, F.; Kärger, L.
2024, July 5. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Overmolding of 3D Skeleton Winding Structures: Process effects and challenges for process modeling
Dohmen, C.; Meyer, N.; Haas, J.; Beck, B.; Wittemann, F.; Kärger, L.
2024, July 5. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Dohmen, C.; Meyer, N.; Haas, J.; Beck, B.; Wittemann, F.; Kärger, L.
2024, July 5. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Homogenization of the Anisotropic Thermal Conductivity of Mesostructures in Material Extrusion
Hof, L.; Frölich, F.; Wittemann, F.; Kärger, L.
2024, July 2. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Hof, L.; Frölich, F.; Wittemann, F.; Kärger, L.
2024, July 2. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Effects of varying fibre distribution in closed injection pultrusion modelling
Poppe, N.; Zeeb, G.; Wittemann, F.; Wilhelm, M.; Kärger, L.
2024, July 3. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Poppe, N.; Zeeb, G.; Wittemann, F.; Wilhelm, M.; Kärger, L.
2024, July 3. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Evaluation of mechanical properties characterization of additively manufactured components
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A. L.; Wittemann, F.; Kärger, L.; Liebig, W. V.
2025. Progress in Additive Manufacturing, 10 (2), 1217–1229. doi:10.1007/s40964-024-00700-2
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A. L.; Wittemann, F.; Kärger, L.; Liebig, W. V.
2025. Progress in Additive Manufacturing, 10 (2), 1217–1229. doi:10.1007/s40964-024-00700-2
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
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
Schnelle Methode zur Approximation von Druck- und Faserorientierungsverteilung infolge prozess- und materialbedingter Streuungen im Spritzguss
Wittemann, F.; Kärger, L.
2023. NAFEMS-Magazin, 68 (4), 22–28
Wittemann, F.; Kärger, L.
2023. NAFEMS-Magazin, 68 (4), 22–28
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)
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)
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
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
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
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. KIT Scientific Publishing. doi:10.5445/KSP/1000148499
Wittemann, F.
2022. KIT Scientific Publishing. doi:10.5445/KSP/1000148499
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
Wittemann, F.
2022, February 16. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000142956
Theoretical approximation of hydrodynamic and fiber-fiber interaction forces for macroscopic simulations of polymer flow process with fiber orientation tensors
Wittemann, F.; Kärger, L.; Henning, F.
2021. Composites. Part C, Open access, 5, Art.-Nr. 100152. doi:10.1016/j.jcomc.2021.100152
Wittemann, F.; Kärger, L.; Henning, F.
2021. Composites. Part C, Open access, 5, Art.-Nr. 100152. doi:10.1016/j.jcomc.2021.100152
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
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
Injection molding simulation of short fiber reinforced thermosets with anisotropic and non-Newtonian flow behavior
Wittemann, F.; Maertens, R.; Kärger, L.; Henning, F.
2019. Composites / A, 124, 105476. doi:10.1016/j.compositesa.2019.105476
Wittemann, F.; Maertens, R.; Kärger, L.; Henning, F.
2019. Composites / A, 124, 105476. doi:10.1016/j.compositesa.2019.105476