Additive manufacturing of conformal cooling channels for improved injection molding performance

Purpose Achieving balanced cooling for the core and cavity in the injection molding process is challenging, particularly for complex-shaped parts. This study aims to explore the use of selective laser melting (SLM) additive manufacturing to design and fabricate conformal cooling channels (CCC) within mold inserts. The purpose of this paper is to enhance the cooling efficiency, reduce cycle time and improve part quality compared to conventional cooling designs. Design/methodology/approach The research follows a systematic approach to optimizing cooling channels for commercial plastic parts. Finite element analysis (FEA) was performed using ANSYS Workbench to evaluate thermal performance. Additionally, AUTODESK Moldflow Insight software was used to simulate the injection molding process. Findings The proposed 3D-printed conformal cooling inserts demonstrated higher thermal efficiency, significantly reducing cooling time and minimizing temperature variations across the mold cavity. The FEA results confirmed improved heat dissipation and reduced thermal stress, leading to better dimensional stability and reduced defects in molded parts. Social implications The adoption of additive manufacturing in mold design enables faster, high-quality production while promoting sustainable and energy-efficient manufacturing practices. This innovation helps industries meet growing consumer demands by improving thermal regulation, reducing cycle time and minimizing material waste and environmental impact. Originality/value This study introduces a novel approach to integrating CCCs into injection mold inserts using SLM-based additive manufacturing. The findings provide valuable insights for the future development of high-performance mold tooling in the plastics industry.