3D-printed mold inserts with cooling channels that follow your part geometry — reducing injection molding cycle time by 15–72%, eliminating gate burn marks, and increasing output by up to 73%.
Conformal cooling is a mold cooling method in which the cooling channels follow the contour of the molded part — rather than running in straight lines as in conventional drilling.
Because the channels are positioned close to the mold surface at every point, heat is extracted more uniformly and efficiently. This is only possible with metal 3D printing (SLM/LPBF) — conventional drilling can only produce straight holes.
Channels positioned at the hottest, most critical locations on the insert
Double-helix channels for cylindrical cores to prevent deflection
Multiple channels designed simultaneously for complex geometry
1.5mm diameter channels in spaces machining cannot reach
Validated with Moldex3D thermal simulation before printing
Uniform heat extraction allows parts to reach ejection temperature faster. Proven 15–72% cycle time reduction across 13 case studies.
Uneven cooling causes warpage, sink marks, and residual stress. Conformal cooling eliminates the temperature gradients that cause these defects.
For transparent materials (PETG, MS, PC), gate burn marks are common when mold temperatures are too high. Conformal cooling keeps the gate area cool.
Shorter cycle + fewer rejects = more good parts per hour from the same machine. Our customers have seen 15–73% output increases.
More parts per hour + fewer defects = lower cost per good part. Unit cost reductions of ¥0.11–¥3.60 documented across our case studies.
Consistent, controlled cooling reduces thermal fatigue. Combined with high-hardness tool steel (50–55 HRC), insert service life is significantly extended.
Every number is from a real customer project. Before and after conformal cooling.
| Application | Industry | Conventional | Conformal | Improvement | Output ↑ | Cost ↓ |
|---|---|---|---|---|---|---|
| Cosmetics packaging | Cosmetics | 21s | 6s | 72% | — | — |
| Automotive trunk rod | Automotive | 60s | 40s | 34% | +36% | ¥0.45 |
| Rearview mirror shaft | Automotive | 50s | 38s | 24% | +32% | ¥0.34 |
| Brake fluid reservoir | Automotive | 41s | 29s | 30% | +41% | ¥0.34 |
| Daily care bottle cap | Daily Care | 14s | 10s | 28.5% | +40% | ¥0.11 |
| MOUTAI liquor bottle cap | Spirits | 100s | 70s | 33.3% | +43% | ¥0.83 |
| Eye cream jar | Cosmetics | 60s | 50s | 17% | +20% | ¥0.28 |
| Compact powder case | Cosmetics | 47s | 40s | 15% | +18% | — |
| Lotion pump bottle cap | Cosmetics | 65s | 50s | 24% | +31% | — |
| Xiaomi humidifier | Home Appliances | 90s | 60s | 33% | +50% | ¥3.60 |
| Solar panel bracket | Energy | 50s | 38s | 24% | +32% | ¥0.33 |
| E-cigarette tip | Consumer Electronics | 28s | 20s | 30% | +40% | ¥0.22 |
| Medical deep-hole plate | Medical | 45s | 26s | 43% | +73% | ¥0.90 |
We receive your part drawing or existing mold design. Our engineers identify hot spots and determine the optimal cooling channel layout using Moldex3D thermal simulation.
Using NX or SolidWorks, we design internal cooling channels that closely follow your part surface. Multiple channels can be designed simultaneously, including double-helix configurations.
We run Moldex3D thermal simulation to validate cooling time, temperature uniformity, and potential warpage — before printing.
The insert is printed in 420 mold steel or 18Ni300 maraging steel using SLM (selective laser melting) on our BLT and E-Plus machines.
Stress relief + age hardening to achieve 50–55 HRC. Support structure removal. The insert is now ready for precision finishing.
CNC finishing to final tolerances. Polishing up to SPI-A1 for transparent products. Inspection, packing, and global shipping.
| Material | Best For | Hardness |
|---|---|---|
| 420 Mold Steel | General injection mold inserts | 50–52 HRC |
| 18Ni300 Maraging | High-performance, long-run molds | 52–55 HRC |
| MS1 | Cost-effective standard inserts | 50–52 HRC |
| M2 | High-wear, high-cycle tooling | 53–55 HRC |
All materials meet SPI-A1 polishing standard. High mold density — suitable for transparent injection molded products.
Conformal cooling gives the greatest benefit when:
Your part has deep ribs, bosses, or complex 3D geometry
You're experiencing gate burn marks or surface defects
Cycle time is limiting your production capacity
You're molding transparent or optical-grade plastics (PETG, MS, PC)
Part warpage is causing dimensional issues
You're using a hot runner system
We'll design the conformal cooling layout and reply within 24 hours.
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