Conformal Cooling Case Studies

Problem: High mold temperature causing gate burn marks on transparent PETG products. Conventional cooling channels could not reach deep rib areas.

Solution: Conformal cooling channels placed at the gate area and deep rib positions using insert-embedded printing. Strategic insert design also reduced material usage.

Metric	Conventional	Conformal	Improvement
Cooling time	21s	6s	72%
Part temperature	93°C	60°C	35.6%
Mold temperature	94°C	62°C	34.4%
Mold temp stability	Unstable	Stable	✓
Gate burn marks	Yes	None	Eliminated

Problem: Uneven cooling causing warpage and poor demolding. Long cycle time, low yield.

Solution: Double-helix conformal cooling channels on the cylindrical core to balance the thermal field and prevent core deflection.

Metric	Conventional	Conformal	Improvement
Cooling time	60s	40s	34%
Mold temperature	80°C	34°C	57%
Warpage	Yes	None	Eliminated
Daily output	1,152 pcs	1,570 pcs	+418 pcs
Unit cost	¥1.87	¥1.42	-¥0.45

Problem: Insufficient cooling — locking pins not performing as expected. Thick walls, short shots.

Solution: Insert-embedded printing in MS1 material for extended service life. Deep rib areas equipped with conformal channels.

Metric	Conventional	Conformal	Improvement
Cooling time	50s	38s	24%
Mold temperature	46°C	30°C	35%
Warpage	Yes	None	Eliminated
Daily output	1,440 pcs	1,895 pcs	+455 pcs
Unit cost	¥1.49	¥1.15	-¥0.34

Problem: Uneven cooling, long cycle, deep ribs prone to warpage and sink marks at top.

Solution: Insert-embedded printing. Deep rib areas equipped with conformal channels to eliminate hot spots.

Metric	Conventional	Conformal	Improvement
Cooling time	41s	29s	30%
Mold temperature	65°C	24°C	41%
Warpage	Yes	None	Eliminated
Daily output	1,756 pcs	2,482 pcs	+726 pcs
Unit cost	¥1.24	¥0.90	-¥0.34

Problem: Gate area prone to burn marks. Thick walls, poor cooling, PETG surface not transparent enough.

Solution: Insert-embedded printing to reduce cost. Internal conformal channels lower insert temperature evenly.

Metric	Conventional	Conformal	Improvement
Cooling time	14s	10s	28.5%
Warpage	Yes	None	Eliminated
Daily output	5,142 pcs	7,200 pcs	+2,058 pcs
Unit cost	¥0.44	¥0.33	-¥0.11

Problem: Deep well cooling ineffective. Uneven thermal field on deep rib areas — product dense, easy to warp.

Solution: Insert-embedded printing. Deep rib areas equipped with conformal channels.

Metric	Conventional	Conformal	Improvement
Cooling time	100s	70s	33.3%
Warpage	Yes	None	Eliminated
Daily output	720 pcs	1,028 pcs	+308 pcs
Unit cost	¥2.83	¥2.00	-¥0.83

Problem: Gate area burn marks. Thick walls, poor cooling, PETG surface not transparent enough.

Solution: Insert-embedded printing. Deep rib conformal channels for even thermal distribution, less warpage, improved surface clarity.

Metric	Conventional	Conformal	Improvement
Cooling time	60s	50s	17%
Gate burn marks	Yes	None	Eliminated
Daily output	1,200 pcs	1,440 pcs	+240 pcs
Unit cost	¥1.87	¥1.59	-¥0.28

Problem: Gate area burn marks on transparent PETG compact case. Thick walls, poor cooling.

Solution: Insert-embedded printing. Deep rib conformal channels for even thermal distribution.

Metric	Conventional	Conformal	Improvement
Cooling time	47s	40s	15%
Gate burn marks	Yes	None	Eliminated
Daily output	1,531 pcs	1,800 pcs	+269 pcs

Problem: Thick walls, overheating, nozzle sticking, poor cooling — MS-material surface not transparent.

Solution: Insert-embedded printing. Deep rib conformal channels for even thermal transfer and improved surface clarity.

Metric	Conventional	Conformal	Improvement
Cooling time	65s	50s	24%
Gate burn marks	Yes	None	Eliminated
Daily output	1,100 pcs	1,440 pcs	+340 pcs

Problem: Uneven cooling, difficult demolding — part pulls during ejection. Very long injection cycle.

Solution: Conformal channels placed at heat-concentrated areas. Insert-embedded printing combined with conventional tooling for cost-optimized solution.

Metric	Conventional	Conformal	Improvement
Cooling time	90s	60s	33%
Mold temperature	62°C	48°C	22.5%
Warpage	Yes	None	Eliminated
Daily output	880 pcs	1,320 pcs	+440 pcs (+50%)
Unit cost	¥13.60	¥10.00	-¥3.60

Problem: Uneven cooling leads to long cycles. Deep hole drilling for cooling is ineffective. Short mold life.

Solution: Conformal channels at heat-concentrated deep positions. MS1 mold steel for extended service life.

Metric	Conventional	Conformal	Improvement
Cooling time	50s	38s	24%
Mold temperature	46°C	30°C	35%
Short shots	Yes	None	Eliminated
Daily output	1,440 pcs	1,895 pcs	+455 pcs
Unit cost	¥1.89	¥1.56	-¥0.33

Problem: Long cycle time. Cavity space too small for conventional cooling channels to be placed near critical areas.

Solution: 1.5mm diameter circular conformal cooling channels placed inside cavity walls — enabling effective heat extraction where conventional drilling cannot reach.

Metric	Conventional	Conformal	Improvement
Cooling time	28s	20s	30%
Mold temperature	65°C	24°C	41%
Surface defects	Yes	None	Eliminated
Daily output	2,570 pcs	3,600 pcs	+1,030 pcs
Unit cost	¥0.98	¥0.76	-¥0.22

Problem: Thin surrounding walls and limited floor space — conventional machining cannot place cooling channels close enough.

Solution: Conformal cooling channels placed along all four walls and the base, surrounding the cavity for complete thermal coverage.

Metric	Conventional	Conformal	Improvement
Cooling time	45s	26s	43%
Mold temperature	46°C	30°C	35%
Short shots	Yes	None	Eliminated
Daily output	1,760 pcs	3,046 pcs	+1,286 pcs (+73%)
Unit cost	¥3.50	¥2.60	-¥0.90