This simulation-based case study demonstrates how conformal cooling channels—enabled by hybrid manufacturing—improve mold cooling efficiency and reduce cycle time.
Compared to traditional straight-line channels, conformal paths maintain uniform heat extraction, leading to measurable performance gains.
Case Study Overview
Project: Automotive connector mold
Material: H13 tool steel
Manufacturing method: Hybrid metal 3D printing + CNC machining
Objective: Compare traditional vs. conformal cooling using thermal simulation and production testing
Simulation Setup
| Parameter | Traditional Cooling | Conformal Cooling |
|---|---|---|
| Cooling path geometry | Straight drill lines | Contoured channels (3D spline) |
| Proximity to hot zones | 8–12 mm | 2–5 mm |
| Channel diameter | Constant | Variable (optimized for flow) |
| Software used | Autodesk Moldflow, ANSYS | Autodesk Moldflow, ANSYS |
Thermal loads, flow rates, and boundary conditions were identical for both designs.
Performance Results
| Metric | Traditional Mold | Conformal Mold | Improvement |
|---|---|---|---|
| Average cycle time | 28 seconds | 20 seconds | –28.6% |
| Peak mold surface temperature | 92°C | 74°C | –19.6% |
| Part warpage | 0.45 mm | 0.22 mm | –51.1% |
| Cooling uniformity deviation | ±6.8°C | ±2.1°C | –69.1% |
| Mold thermal fatigue risk | High | Low | Reduced stress |
Post-Processing and Validation
The conformal design was printed using DMLS and finished using precision CNC machining services.
Final steps included:
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Machining of mating faces and ejector holes
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Leak testing of cooling channels
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Cycle testing under production load (100,000+ shots)
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Visual inspection and dimensional validation
Result: The hybrid mold delivered better cooling, dimensional stability, and a longer maintenance interval.
Lessons Learned
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Simulation must guide the placement and diameter of conformal paths
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Additive designs should always account for CNC access during post-processing
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Thermal efficiency directly improves mold uptime and part quality
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Hybrid molds offer the best ROI when cooling affects part tolerance or cycle time
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