Ford parts. Recycled plastics. Industrial-grade control.
Recycled plastics are critical for circular manufacturing. But they also create a hard production problem: material variability.
When the input material changes, the injection molding process must adapt. Otherwise, quality drops, scrap increases, and recycled-content production becomes difficult to scale.
Simularge is developing a physics-based digital twin for injection molding within the EcoPlast Horizon Europe project, in collaboration with Assan Hanil and Ford Otosan.
The focus is direct: manufacturing Ford automotive plastic parts with higher recycled and sustainable material content, while keeping quality and process stability under control.
In the project, Assan Hanil will manufacture Ford parts using recycled and sustainable material formulations supplied through the EcoPlast value chain. The injection molding process will be monitored and controlled by Simularge’s digital twin against compositional variation in the input material.
The digital twin will support:
Process optimisation for injection molding
Better control of recycled-content materials
Quality prediction for molded parts
Faster response to material variability
Reduced scrap and production waste
More stable, repeatable automotive plastic production
EcoPlast sets measurable targets for the manufacturing layer:
Digital twin prediction accuracy: >90%
Digital twin response time: <15 seconds
Scrap rate: ≤1%
Process optimisation error rate: <1%
Waste target: <5%
Efficiency improvement target: ≥10%
Simularge makes recycled-content injection molding predictable, controllable, and ready for industrial scale.
Contact us to assess how a physics-based digital twin can make recycled-content injection molding more predictable and controllable in your production process.
References:
SIMULARGE
Unlocked Hidden Data from Legacy Injection Molding Machines
See how Simularge gave legacy injection molding machines live visibility in under 2 weeks, with no hardware changes and 99% accuracy.
BEKO
How Beko saved 2M Euro every year in Thermoforming Digital Twin
See how Beko used Simularge's digital twin to reach 96% thermal accuracy, improve OEE by 20% and save €2M annually.
Digital Twin for Composite Autoclave Manufacturing
Improve composite autoclave curing with a physics-based digital twin for shorter cycles, fewer defects, and consistent part quality.
Ready to get started ?
If this challenge sounds familiar, let’s discuss how Simularge’s physics-based digital twin technology can be applied to your production environment.
