Modeling Options in Injection Molding Simulation

Injection molding is one of the most widely adopted manufacturing methods in the plastics industry, owing to its high efficiency, design flexibility, and mass production capabilities. Throughout the development and application of Injection molding technology, trade-offs are pervasive, arising from competing requirements such as processability versus material performance, productivity versus quality, and simplicity versus functionality. Injection molding simulation itself embodies such trade-offs, as it is used to design increasingly complex processes and mold systems to achieve improved material properties and part performance, while inevitably balancing physical accuracy against computational efficiency and modeling cost. This review examines typical modeling options in injection-molding simulation from an accuracy–complexity trade-off perspective. The modeling strategies adopted in the primary stages of the molding cycle—namely, the injection, packing, and cooling phases—are systematically reviewed, with emphasis on how simplifying assumptions are introduced to manage numerical complexity. By organizing existing research through the lens of qualitative trade-offs, this review aims to support a more structured understanding of model selection in injection molding simulation for both academic studies and industrial applications.