by Arnaud Divialle
Conformal cooling promises to greatly improve part quality, cycle times and energy efficiency in plastic injection molding.
But are the benefits worth the added costs?
The benefits of conformal cooling
Conformal cooling channels deliver fast, uniform cooling, which translates into shorter cycle times, better quality parts, and more profitability.
The benefits of conformal cooling include:
- Design flexibility
- Improved heat transfer efficiency for faster, more uniform cooling
- Fewer common defects, such as warpage, shrinkage and sink marks
- Reduced material costs and waste
- Lower operational costs and energy consumption
Reduced cycle time
In plastic injection molding, as much as 80% of the total cycle time is devoted to cooling, especially for complex parts. Conformal cooling channels transfer heat more efficiently. As a result, parts cool quicker, making the overall cycle time significantly shorter – in some cases reducing it by as much as 40% – compared to traditional molds.
Improved part quality
By providing more uniform cooling across the part and the mold, conformal cooling minimizes common defects, such as warpage, shrinkage, and sink marks.
Parts molded using conformal cooling often have a better surface finish and less internal stress. This leads to a better dimensional accuracy and lower scrap rate, reducing material costs and waste for an added environmental and financial benefit.
Energy efficiency
Shorter cooling times and optimized thermal management can reduce energy consumption. Plus, conformal cooling lines tend to be shorter and smoother with lower pressure drops. As injection molding machines often operate continuously, less time spent cooling each cycle means lower operational costs and more energy savings. Lower pressure drops need smaller pumps, reducing capital expenditure.
The downsides of conformal cooling
The potential competitive advantage is too good to ignore. But it comes at a cost.
Conformal cooling requires more upfront investment, from higher initial tooling costs to more complex designs, which in turn drive up engineering costs and lead times.
Plus, conformal cooling molds are more challenging to maintain and repair and may not be suitable for as wide a range of materials as traditional methods.
Design complexity
Designing conformal cooling channels requires advanced software, simulation tools, and skilled engineers who will need to spend more time designing an efficient cooling layout. The complexity of these designs can increase engineering cost and lead times.
Maintenance and repair
Conformal cooling molds are more difficult to maintain and repair than traditional molds. The complex 3D channels can be harder to clean, and buildup or clogging ("scaling") within these channels can hinder performance. And, if a conformal cooling channel is damaged, repairs and modifications are likely to be more complicated and expensive due to the custom design and additive manufacturing process.
Limited material options
Conformal cooling molds are typically made using metal alloys compatible with 3D printing technologies. But, there is a more limited range of materials available for additive manufacturing than for traditional mold-making methods, where hardened tool steels may be used for greater durability. In industries that use abrasive materials or high temperatures, 3D-printed materials may not offer the same longevity as conventionally machined tool steels.
Weighing the pros and cons of conformal cooling
Knowing when it makes sense to spend on conformal cooling – and when it doesn’t – is key.
It’s worth taking the time to carefully evaluating the pros and cons of conformal cooling for your specific situation before making the decision to move ahead or not.
SimForm’s Conformal Cooling ROI Calculator eliminates the guesswork for you
The Conformal Cooling ROI Calculator
Find out quickly and easily whether conformal cooling is right for your plastic injection molding application.
Simply input basic information about your mold specifications and production parameters to get your analysis.
Make the best cooling decisions for your specific plastic injection molding needs.