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A review of the design optimization of conformal cooling channels in injection molds.

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Title: A review of the design optimization of conformal cooling channels in injection molds.
Authors: Silva, Hugo Miguel1 (AUTHOR) hugo.silva@hmsilva.science
Source: International Journal of Advanced Manufacturing Technology. Jun2025, Vol. 138 Issue 7, p2653-2671. 19p.
Subjects: Optimization algorithms, Computer-aided engineering, Computational mathematics, Thermal stresses, Mathematical optimization
Abstract: Recent advancements in additive manufacturing have rendered the creation of conformal cooling channels more accessible and cost-effective. In the injection molding process, conformal cooling channels offer enhanced cooling efficiency relative to traditional straight-drilled channels. The major reason is that conformal cooling channel can adhere to the contours of the molded geometry, but conventional machining methods cannot. Using conformal cooling channel can reduce thermal stresses and distortion, improve cycle time, and provide a more consistent temperature distribution. Conversely, traditional channels use a more complex design method than conformal cooling channel. Simulations of computer-aided engineering (CAE) are essential for developing an efficient and economical design. Design and/or topology optimization techniques can be used to reach optimal solutions. This paper reviews the fundamental methodologies for the design and topology optimization of Conformal Cooling Channels (CCCs) in injection molds. This article aims to present the most relevant optimization techniques that may be used for the optimization of conformal cooling channels in injection molds, to be used as a guide for engineers to be able to select the best optimization method according to the objectives of their project(s). The results highlight the significant advantages of CCC in injection molding, particularly in reducing cooling time, improving thermal uniformity, and enhancing part quality. The comparative analysis of optimization techniques presented provides valuable insights for selecting the most effective method based on project objectives, whether focusing on design complexity, computational efficiency, or real-world validation. Additionally, the integration of computational simulations, optimization algorithms, and experimental validation underscores the importance of a multi-faceted approach in achieving optimal conformal cooling channels' performance. These findings aim to be useful as a practical guide for engineers and researchers aiming to enhance injection molding efficiency through advanced cooling channel design. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: A review of the design optimization of conformal cooling channels in injection molds.
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  Data: <searchLink fieldCode="AR" term="%22Silva%2C+Hugo+Miguel%22">Silva, Hugo Miguel</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> hugo.silva@hmsilva.science</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jun2025, Vol. 138 Issue 7, p2653-2671. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Optimization+algorithms%22">Optimization algorithms</searchLink><br /><searchLink fieldCode="DE" term="%22Computer-aided+engineering%22">Computer-aided engineering</searchLink><br /><searchLink fieldCode="DE" term="%22Computational+mathematics%22">Computational mathematics</searchLink><br /><searchLink fieldCode="DE" term="%22Thermal+stresses%22">Thermal stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Mathematical+optimization%22">Mathematical optimization</searchLink>
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  Data: Recent advancements in additive manufacturing have rendered the creation of conformal cooling channels more accessible and cost-effective. In the injection molding process, conformal cooling channels offer enhanced cooling efficiency relative to traditional straight-drilled channels. The major reason is that conformal cooling channel can adhere to the contours of the molded geometry, but conventional machining methods cannot. Using conformal cooling channel can reduce thermal stresses and distortion, improve cycle time, and provide a more consistent temperature distribution. Conversely, traditional channels use a more complex design method than conformal cooling channel. Simulations of computer-aided engineering (CAE) are essential for developing an efficient and economical design. Design and/or topology optimization techniques can be used to reach optimal solutions. This paper reviews the fundamental methodologies for the design and topology optimization of Conformal Cooling Channels (CCCs) in injection molds. This article aims to present the most relevant optimization techniques that may be used for the optimization of conformal cooling channels in injection molds, to be used as a guide for engineers to be able to select the best optimization method according to the objectives of their project(s). The results highlight the significant advantages of CCC in injection molding, particularly in reducing cooling time, improving thermal uniformity, and enhancing part quality. The comparative analysis of optimization techniques presented provides valuable insights for selecting the most effective method based on project objectives, whether focusing on design complexity, computational efficiency, or real-world validation. Additionally, the integration of computational simulations, optimization algorithms, and experimental validation underscores the importance of a multi-faceted approach in achieving optimal conformal cooling channels' performance. These findings aim to be useful as a practical guide for engineers and researchers aiming to enhance injection molding efficiency through advanced cooling channel design. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-025-15234-2
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        Text: English
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              Text: Jun2025
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