Parametric Design and Finite Element-Based Structural Assessment of Industrial Moulds for Concrete Blocks

The conventional fabrication of concrete block moulds is characterised by persistent challenges related to standardisation, protracted redesign processes, and an absence of structural validation, all of which undermine regulatory compliance. This study proposes a standardised parametric modelling process aimed at ensuring compliance with the technical criteria of the INEN-3066 and ASTM C90 standards. An integrative methodology combining QFD/VOC matrices with CAD-CAE tools was used to parameterise three commercial mould configurations (10, 15, and 20 cm) in SolidWorks 2023. A finite element analysis (FEA) was subsequently conducted in ANSYS 2025 R1 under iterative overloads of up to 10,000 N, complemented by a rheological analysis in SolidWorks Plastics. The results show that the “male” (punch) components exhibit consistently high stiffness, maintaining fatigue safety factors above 1.61 across all three configurations. In contrast, the “female” (die) components are the more vulnerable link in the assembly: the fatigue safety factor of the 10 cm die drops below the required threshold of 1.0 at 4000 N, compared with 6175.6 N and 9254 N for the 15 and 20 cm configurations, respectively. The rheological analysis further confirmed the feasibility of an ultrafast injection cycle, with cavity filling times below 0.11 s and injection pressures ranging from 6.105 to 12.9 MPa across all formats. It is posited that, in accordance with the parametric model, a reinforced-wall geometry should be adopted for the 10 cm die, characterised by an augmentation of wall thickness by 15% and enlarged fillet radii. This is projected to elevate its fatigue-critical load beyond 4500 N without necessitating any alteration in the external block dimensions. These findings indicate that parametric CAD-CAE-CFD digitalisation can anticipate structural failures before manufacturing, offering a computational pathway toward regulatory compliance that should be confirmed through physical prototype testing.