Mold filling analysis software is good at predicting filling patterns, however it is often not trusted when gas-assist enters the equation. The mold filling predictions do not always correspond to the actual gas penetration. With slight corrections, the predictions become more accurate. The images below show a tray and its filling analysis which illustrate the difference in the theoretical (simulation) and the actual molding conditions.

Current mold filling analysis software is used extensively to examine the filling pattern of gas- assisted panel-shaped parts, but struggles in areas where the cross section is large, such as rod shaped parts. Mold filling analysis was compared to actual molding in a study performed on a scoop mold. The figures below compare the mold filling analysis predictions to actual measured averages of percent polymer in molded parts. The software predictions are not always accurate and tend to predict less gas coring and a subsequent increased residual wall thickness. This could cause problems when structural calculations are made. Furthermore, computer analysis does not look at the cross section of the part, much less irregular cross sectional shapes. Three-dimensional mold filling software shows promise and may eventually resolve this problem. However, the only way to really examine this is through experimental study.