What is Conformal Cooling in Injection Molding?

Traditional cooling mechanisms designed in straight lines only provide coverage to a partial outline of the part’s geometry in the mold. Conformal cooling lines are 3D printed to reach all the unique contours of a part’s geometry in the mold or tooling inserts. Conformal lines are therefore less restricted as to where they are placed in the tooling.

Temperature control is crucial in injection molding, as the mold heats up as molten plastic is injected into it. With conventional cooling techniques, the temperature of the mold often rises over the threshold for ejecting a successful part–wasting time and money while the mold cools to an acceptable temperature for part ejection. Conformal cooling, however, maintains a nominal temperature, allowing for a more rapid temperature reduction so that the overall cycle times are reduced each time the mold opens and closes.

3D Design and Printing for Conformal Cooling

When considering conformal cooling as a solution, we analyze both the part and associated mold details to identify which would benefit most from conformal cooling inserts. These details could be mold cores, cavities, slide faces, lifters, or any combination of these. We then design a cooling strategy so that optimum cooling conditions are realized. This process often makes feasible the ability to cool areas not adequately addressed such as radiused corners or tall or thick ribbed details. Above all, it allows for the cooling lines to “conform” to the actual part geometry. The result creates opportunities for broader process windows and process controls, resulting in reduced overall cycle time.

3D printing and conformal cooling create endless possibilities for engineers engaged in industrial manufacturing. Some consider conformal cooling to be one of the most important uses for 3D printing today, highlighting two of this technology’s greatest benefits: freedom in design, and the ability to create sophisticated geometries previously impossible via traditional manufacturing.

Although we provide a variety of services, our engineers typically use Direct Metal Laser Melting (DMLM) to open up more opportunities in design and production for examples like traditionally drilled machined water lines. For that type of project, conformal cooling makes a tremendous difference in production as the process allows lines filled with water to follow the complex shape–including cross sections–of each part.

DMLM additive manufacturing technology makes it possible to customize your small-to medium-sized parts and inserts in days rather than the weeks or months associated with traditional manufacturing. This metal 3D printing process expands freedom in design-driven manufacturing, produces extremely high-quality, repeatable injection molded parts, and accelerates production on every level, improving time to market.

When Should I Use Conformal Cooling?

We recommend conformal cooling (especially for plastic injection molding) when:

• Cycle times are longer than predicted or budgeted.
• The dimensional integrity of your molded parts is non-conforming.
• Traditional manufacturing methods are limiting your mold’s cooling features.
• Improper cooling is causing deformed parts, resulting in excessive scrap costs.

Shapeways Process

Our engineers performed a recent study, further validating this process. In the example studied, results demonstrated a 69% reduction in cooling time. Software analysis also verified that the modified sample cooling channels revealed a more uniform temperature distribution when compared to the original cooling design.

During actual manufacturing environments, our customers running 70-80 parts an hour with traditional cooling lines or channels typically increase their output to an impressive 140 parts an hour with 3D printed conformal cooling inserts.

Shapeways for Conformal Cooling

The impact and efficiency of conformal cooling can transform production for your company, and accelerate growth. In 2022, Shapeways further expanded its traditional manufacturing capabilities with the acquisition of Linear AMS, an expert in injection molding known for innovative solutions like conformal cooling. Linear’s true, consultative approach made them a trusted partner in solving the toughest manufacturing challenges and Shapeways has continued with that legacy.

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What is Conformal Cooling?

Conformal Cooling is a manufacturing technique that involves creating cooling channels or passages within a tool or mold that conform to the shape of the part being manufactured. Conformal cooling is most often used in plastic injection molding to reduce cycle times and improve part quality.

How Does Conformal Cooling Reduce Mold Cycle Time?

Conformal cooling provides precise heat regulation, optimizing cooling rates, and significantly reducing cycle times. Traditional cooling mechanisms designed in straight lines only provide coverage to a partial outline of the part’s geometry in the mold. Conformal cooling channels, however, are 3D printed to reach all the unique contours of a part’s geometry in the mold or tooling inserts.
Temperature control is crucial in injection molding, as the mold heats up when molten plastic is injected into it. With conventional cooling techniques, the temperature of the mold often rises over the threshold for ejecting a successful part–wasting time and money while the mold cools to an acceptable temperature for part ejection. Conformal cooling maintains a nominal temperature, allowing for a more rapid temperature reduction so that the overall cycle times are reduced each time the mold opens and closes.

By implementing conformal cooling, businesses can achieve remarkable results in terms of increased productivity and profitability. With cycle time savings, machinery and resources are freed up to produce other parts, unlocking manufacturing capacity.

In addition to these benefits, the efficient heat regulation provided by conformal cooling significantly improves overall efficiency. By optimizing cycle times, companies can allocate resources more effectively and avoid the need for additional equipment.

Materials Advanced by Conformal Cooling

Conformal cooling plays a pivotal role in improving quality of part production with a variety of materials, including nylon. Mold temperatures are quickly and subtly adjusted, allowing for precise control.
For materials that are heated to extremely high temperatures and require a more contracted cooling process, our engineers are also currently exploring variations like ‘conformal heating,’ using hot oil instead of water to cool molds when dealing with high-temperature materials.
Our engineers typically 3D print the cooling inserts in materials like Steel. Advanced technology like Direct Metal Laser Melting (DMLM) opens up endless opportunities in design and production making it possible to 3D print lines that follow the complex shape–including cross sections–of each part.

Avoiding Dimensional Issues

Quality or dimensional issues often stem from an inability to control the thermal delta (or heat difference) across the expanse of a part. High scrap rates, warpage, and distortion are all typical symptoms of uneven cooling. Conformal cooling helps maintain the dimensional integrity of the part, ensuring consistent quality and reducing waste.

While a typical customer may be running 50 to 80 parts an hour traditionally, with 3D printed conformal cooling inserts they can look forward to upwards of 140 parts per hour, making a huge difference in productivity for every manufacturing job.

What are Applications for Conformal Cooling?

There are a variety of parts and features that can benefit from using conformal techniques, across multiple industries. Objects like cups with handles, are a great example. Conformal cooling minimizes the potential for dimensional issues like shrinkage, distortion, warpage, and loss of structural integrity. Instead, manufacturers enjoy uniformity in parts, consistent quality for high-performing parts, and reduced waste during production.
To identify suitable applications for conformal cooling software like Moldex3D can be used for comprehensive analysis of molds, simulating flow patterns, cooling efficiency, and identifying potential issues like hot spots. This powerful software helps provide detailed data and visualizations, enable fine-tuning of conformal cooling parameters, and enhances part quality—allowing manufacturers to optimize production efficiency and produce larger volumes of parts.

Why do Manufacturers Use Conformal Cooling?

Manufacturers gain a significant edge in today’s competitive landscape with the ability to identify the correct applications and uses for conformal cooling. Efficient temperature regulation, reduced cycle times, improved part quality, and increased productivity are just some of the benefits offered by conformal cooling.
By leveraging the transformative potential of conformal cooling, businesses can thrive in a competitive market, setting new standards for productivity and excellence. See how Shapeways can help manufacturers with their conformal cooling needs.

Shapeways for Conformal Cooling

The impact and efficiency of conformal cooling can transform production for your company, and accelerate growth. In 2022, Shapeways further expanded its traditional manufacturing capabilities with the acquisition of Linear AMS, an expert in injection molding known for innovative solutions like conformal cooling. Linear’s true, consultative approach made them a trusted partner in solving the toughest manufacturing challenges and Shapeways has continued with that legacy.

The post What is Conformal Cooling? | Shapeways appeared first on Shapeways Blog.

Founded in 2007, Eastern Rail Corporation built a reputation on designing sustainable, high-quality solutions for the Metro Rail infrastructure in the US. For a specific component—an insulator that isolates the electrified third rail in underground subway systems–Eastern Rail needed to update the material to meet safety standards. A switch to Polyphenylene Sulfide (PPS) subsequently required a reevaluation of the existing mold. To tackle this issue, Eastern Rail approached Linear AMS, a Shapeways Company, seeking partnership in creating an innovative solution to enhance functionality and efficiency.

Eastern Rail is a long-standing customer, supporting transit agencies in metropolitan areas like New York City, Washington, D.C., and Miami, where urban rail systems frequently operate in underground tunnels. Such an environment demands components with specific dielectric properties, safeguarding against unwanted electrical charges and allowing for more effective management of underground train lines.

Incorporating Advanced Cooling Technology

Injection molding manufacturers often face challenges related to long cycle times, part quality, and overall efficiency. Conformal cooling technology specifically resolves these problems. Relying on 3D printing for customization and efficiency, conformal cooling adapts to fit into industrial molds. 

In contrast to conventional methods, which are restricted to machining in straight lines, conformal lines are designed to follow the shape of the part itself–leading to a more consistent temperature throughout the part’s cooling stage. This means that parts are less likely to warp, while also cooling up to 50% faster. With conformal cooling, manufacturers can reduce their cycle time and increase their throughput, all while improving part quality. 

For Eastern Rail, integrating this technology produced more consistent temperatures in tooling, leading to more efficient production cycles, satisfying stringent requirements for reliable and efficient rail systems.

Improving Tooling for Complex Materials

Initially, Eastern Rail encountered challenges due to the complex part design and core mold features, combined with the nature of Xencor PPS LGF-3045, a 45% long-glass, fiber-reinforced Polyphenylene Sulfide (PPS).

While providing beneficial properties like heat resistance and durability, PPS also presents manufacturing difficulties. Linear performed a comprehensive analysis, revealing that Eastern Rail’s existing tooling with conventional cooling–in combination with a PPS material–would not produce a moldable part.

“I was aware a new approach would be necessary with the change in material,” said Mickey Morales, CEO of Eastern Rail. “After working with Linear for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”
To address these issues, Linear and Eastern Rail worked side-by-side for months in prototyping and testing, experimenting with molds and the integration of 3D printed conformal cooling lines.

Upon initial review, the team suggested making the change to a steel mold over aluminum for production volumes. The PPS material is highly corrosive and would deteriorate the aluminum mold. Transitioning to a steel mold also opened up the possibility of using conformal cooling to allow for better thermal control. Additionally, based on the molding temperature requirements of PPS, the team determined hot oil would be necessary to maintain tool temperature, as opposed to water which is more commonly used.

“The shift to steel molds significantly transformed our approach, working much better with the unique characteristics of PPS and the need for a precise, controlled molding environment,” said John Tenbusch, Director of Automotive Sales at Shapeways.

“After working with Linear [A Shapeways Company] for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”

Mickey Morales, CEO of Eastern Rail

Reducing Cycle Times & Improving Part Quality

The introduction of conformal cooling was highly effective, yielding a remarkable improvement in efficiency after Linear introduced steel tooling. Implementing conformal cooling led to a design adjustment that significantly cut costs. Interchangeable inserts, usually requiring three cores, were reduced to just one.

“We had to incorporate cooling one way or another,” said David Dickerson, Manager of Client Services at Shapeways. “Without conformal cooling, we couldn’t have made the interchangeable parts we needed for the various sizes of the insulator.”

With the new steel molds and conformal cooling inserts, the Linear team was able to reduce the cycle time from 181 seconds to 138 seconds, reflecting a 23% improvement. Reduced production time allows for more parts to be made, lowering both piece cost and overall program cost, without sacrificing part quality. The more even, controlled temperatures also led to the production of higher-quality, more reliable parts.

While the initial prototyping and testing phase required significant time and financial investment, the cost savings over the long term more than justified the upfront expenditure. The enhanced material durability, lower maintenance needs, and increased production speeds collectively contributed to significant long-term economic advantage for Eastern Rail.

“While we encountered a few obstacles during our journey, Linear’s team of experts was again able to provide a highly engineered solution while providing cost-saving benefits,” said Mickey Morales, CEO of Eastern Rail.

Aligning with Regulatory and Environmental Considerations

Eastern Rail’s openness to new solutions enabled improvements with both short and long-term benefits, meeting industry-specific needs while maintaining a commitment to environmentally friendly materials and regulatory compliance.

This case study offers useful problem-solving insights for issues related to materials, tooling, and cooling. These solutions may be applicable to other manufacturing sectors as well. Overall, this project showcases the value of teamwork, innovation, and excellence in manufacturing

Find out more about how Shapeways can collaborate with your company.

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