New Converse Connector Closes the Loop for Injection Molding Part Design
In injection molding part design, one of the biggest challenges has always been bridging the gap between process simulation and structural analysis. While process simulations can capture crucial details such as fiber orientation and material behavior, these insights are often lost or oversimplified when passed on to structural analyses. The result is conservative assumptions, inefficient designs, and longer development cycles.
The new Converse Connector for the Synera Platform changes this by enabling a smooth, automated connection between process and structural domains, removing sometimes time-consuming manual steps in the workflow.
For fiber-reinforced thermoplastics, the actual fiber orientation and resulting mechanical behavior are directly determined by the molding process. When those effects aren’t accurately reflected in structural analysis, performance predictions can deviate significantly from reality and leading to potential over-engineering, unnecessary weight, or unexpected failures.
Traditionally, this hand-off between process and structural simulation has required certain manual effort: exporting simulation results, defining material models, aligning meshes, and setting up analyses repeatedly after every design change. Each iteration took valuable time and carried a risk of data inconsistencies.
The Converse Connector automates the transfer of process data, such as fiber orientation and anisotropic material behavior into the structural analysis model. Integrated directly into Synera FE workflows, it eliminates the need for tedious manual mapping and data preparation.
With this automated approach:
- Simulation results from the molding process can be seamlessly used to inform structural performance predictions.
- Engineers can run design iterations faster and more consistently.
- Non-specialists can access validated workflows without needing deep simulation expertise.
- More realistic part behavior is considered early in the design process, supporting better decisions and leaner parts.
As pressure grows to create lighter, more efficient, and more cost-effective components, development teams are looking for smarter ways to connect their design and simulation activities. Realistic material representation isn’t just a “nice to have” anymore. It’s a critical factor for reliable performance, fewer prototypes, and faster time to market.
The Converse Connector provides exactly that: a robust, automated bridge that closes the loop between process and structural simulation.
This release marks an important step towards more connected and automated product development workflows, as it was demostrated at this years Synera Connect User Meeting. In the future, we can expect even deeper integrations, smarter automation, and closer ties to digital twins and manufacturing systems and further accelerating how engineering teams design and validate parts.
For companies aiming to modernize their design process, this innovation signals a clear shift: manual hand-offs and fragmented workflows are being replaced by seamless, automated simulation chains that deliver speed, accuracy, and confidence.
Author: Andrew Sartorelli, Head of Product Management at Synera GmbH, Bremen, Germany
