Meaning
Material mapping software transfers fibre orientation, residual stress and temperature fields from polymer processing simulation meshes onto structural finite element analysis meshes. In structural component design, digimat-map projects non-uniform microstructural data from injection moulding tools onto crash, fatigue or NVH structural simulation models. The software preserves local anisotropic property variations across dissimilar element formulations.
Its calculation scope ends at data transfer and mapping verification, leaving subsequent mechanical load solving to external finite element solvers.
Mesh Alignment
Coordinate positioning routines align the injection moulding cavity geometry with the structural engineering model. Shell and tetrahedral elements from filling simulations project their state variables onto solid, shell or continuum structural meshes. The software computes spatial intersection volumes to weigh orientation data onto target elements.
Accurate spatial superimposition prevents orientation shifts across thin-walled ribs, boss features and curved surfaces.
Property Projection
Mapped tensor fields define localized mechanical stiffness across every structural element. The projection preserves the through-thickness skin-core-skin fibre orientation distribution characteristic of injection-moulded composites. Weld line locations map as strength reduction factors, capturing localized embrittlement where advancing flow fronts join.
Transfer errors drop below acceptable thresholds through automated mesh refinement near critical structural boundaries.
Engineering Integration
Automotive and industrial component developers rely on mapped material states to eliminate over-engineering in lightweight thermoplastic structures. Unreinforced resins behave isotropically, but thirty-percent glass-filled polyamides demand accurate structural mapping to predict crash impact performance and burst pressures. Regrind resin lots introduce shorter average fibre lengths, requiring updated orientation-to-property conversion matrices.
Design teams verify mapping quality by evaluating cross-mesh error distributions before running non-linear structural simulations.
