Conformal Cooling

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Table of Contents
Description
Page Number
1.0 Description Conformal Cooling
3
1.1 Traditional Cooling Line Drawbacks
1.2 Case Study, Cooling Options
5
1.3 Engineering Elements, Process Flow
1.4 Conformal Cooling Process Steps 7
2.0 Benefits
8
2.1 Benefits contd
9
3.0 Applications of Conformal Cooling
3.1 Industry Applications
11
3.2 Conformal Cooling Process Considerations
4.0 Design Guidelines 13
4.1 Design Guidelines contd
14
4.2 Process Improvement 15
5.0 Supply Base
16
5.1 Supplier Information
17
6.0 Technology Alternatives
18
7.0 Summary
19

4
6

10
12

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1.0 Description Conformal Cooling

Conformal cooling refers to cooling channels that conform to the surface of the
mold cavity. Conforming cooling channels can demonstrate improvements in
production rate and part quality as compared with conventional production tools.
With molds using straight line drilling methods the distance from cavity to cooling
channel differs causing uneven heat dissipation in the material. This results in varying
temperature levels on the cavity surface & inconsistent cooling which can produce
internal stresses and warpage. Hot spots, which can occur in conventional molds can
be eliminated with conformal cooling.

Straight line drilling

Conformal Cooing

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1.1 Traditional Cooling Line Drawbacks

Conventional cooling has the following drawbacks:
The distance from cavity to cooling channel differs as only straight line drilling channels
are possible (shown below) and as a consequence the heat dissipation cannot take place
uniformly in the material. This results in
Uneven temperature levels on the cavity surface.
Uneven cooling-down processes resulting in internal stresses and thus negative impact
on part quality (warpage).
On top clogging of dead drilling ends creates areas with zero flow velocity thus facilitating
particulate collection. The drilling procedure itself is not without certain risks: in case of
deep drilling there is always a danger to hit ejector holes (wandering drill), or the drill can
even break. As a consequence, the insert could be scrapped.

Conventional tooling mol

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1.2 Case Study, Cooling Options

Case studies
Maximum value comes by optimizing cooling channels thus conditioning tooling temperature, which
enables an uniform temperature level for the mold. This temperature level is influenced in order to achieve
on the one hand a lower temperature for quicker cooling or higher temperature for better product surface
quality on the other hand. Therefore it has to be decided in every single case between the advantages of a
reduced cycle time (=> process speed) and the molded part quality (=>scrap rate because of warpage,
better surfaces). This compromise has to be taken over into the tool and mold temperature control system
design and the right choice. Conventional cooling channels are drilled into a tool. This limits design to
straight lines, easily accessible by a drill. Tooling cavities can pose limits to position and routing of
conventional cooling channels. While conformal cooling channels can be positioned more freely. Cross
sections can be optimized to mold temperature control requirements.

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1.3 Engineering Elements Process Flow

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1.4 Conformal Cooling Process Steps

The two methods for

constructing conformal cooling
with injection molds are
vacuum brazing & laser
sintering. Vacuum brazing is a
technique of fusing two
separately milled halves
together to create the cooling
channels otherwise
unachievable in straight
drilling. Laser Sintering is a
technique to build up the
intricate cooling channels by
fusing metal powder into a
solid piece layer by layer.

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2.0 Benefits

Cycle average temperature reaches its steady

state value within a single injection cycle.
Conformal cooling channels are close to the
mold surface, the effective thermal mass of the
tool is confined to that region between the
surface and the cooling channels. As a result,
the steady state condition is reached rapidly.
Significance of a cooling scheme that satisfies
the conformal cooling condition is that such a
mold will be subject to excellent temperature
control.
Temperature of the mold surface is close to the
temperature of the cooling liquid. This
temperature control has been shown to result in
both shorter cooling times and better control over
part dimensions.
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2.1 Benefits contd..

Direct Metal Laser Sintering (DMLS)
Tooling inserts lead time reduction
Highly complex tempering system
(not conventionally manufacturable)
Cycle time reduction
Process cost saving
Improved quality of products
Scrap rate reduction
Increased freedom of geometry
LaserCusing
Cycle time reductions of up to 40%
No design restrictions
Increased speeds for profile extrusion
lines
Huge increases in mold life
Increased dimensional accuracy of
molded parts
Sink marks avoided
Easy repair of crashed cores/cavities

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3.0 Applications of Conformal Cooling

This technology can be utilized in the all three of Nypros Global Business
Units. Conformal Cool is most suitable for parts with geometries that
are often difficult to cool. Success in production can only be reached
through quality and cost-effective processes. With the design freedom
that both LaserCusing and DMLS offer, very complex tempering
systems can be achieved in order to drastically reduce the cycle time
in injection molding. At the same time, the quality of the final products
improves.
Nypro Mold is already finding ways to integrate their new LaserCusing
capabilities into the mold making business.

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3.1 Industry Applications

There are several potential applications for conformal cooling. Some of these are currently in
development. Others are now being used in production. The processes currently in place for both
prototype and/or production tooling are as follows:
SS injection molds.
Aluminum injection molds.
Reaction injection molds (RIM) applications.
Steam chest molds (used to produce foam patterns typically for lost foam casting or structural foam
parts).
Limited applications for forming dies.

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3.2 Conformal Cooling Process Considerations

Process considerations
Heating/cooling at critical
parts inside the tool, which
cannot or only hardly - be
reached by conventional
methods, becomes feasible (e.
g. long and lean cores, areas
around hot-runners or small
sliders). Using special copper
heat conductors or other
complex measures becomes
obsolete.
If necessary, it is possible to
undercool mold cavities, thus
reaching optimal cycle times by
minimizing cool down times in
tooling cavities.
An evened out temperature
level can help to
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improve tool life time. This becomes relevant

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4.0 Design Guidelines

Design recommendations for the layout of conformal heating/cooling channels are the
same as the ones given for conventional designed channel. The ultimate objective is the
creation of a mold temperature control system, which enables a constant and adapted
temperature level for the material, during the running injection molding process (observe
recommendations of the material manufacturer), on each point of the molding surface. In
order to achieve this result, the channel diameter should be chosen depending on the
distance between the heating/cooling channel and the cavity. Provided that the design
for the molded part is correct, the product can recrystallize uniformly and efficiently in the
mold after the injection phase, which improves the quality (no internal residual stress
means warp-free product with longer life cycle) and reduces the cycle time.

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4.1 Design Guidelines contd..

In terms of tool geometry
Conformal cooling channels are almost infinite in design & fabrication. This makes it
possible to create an ideal cooling channel in a well defined distance to the cavity. A
conventional drilled cooling mechanism can not achieve this.
Cooling channel cross sections can take almost any shape (e. g. oval vs. round)
Turbulence of the coolant (the desired high Reynolds number) within the system can
thus be controlled by actively choosing different cross sections and by switching
between different cross sections. As a consequence, turbulence inside of the coolant
is generated, close to cavity along the whole path of the channels. A bended path
should improve in most of the cases this effect.
Changing cross sections or forking the cooling channel can easily be done without
splitting up the form. This allows for additional heat/cooling advantages in areas that
cannot be reached by conventional methods.

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4.2 Process Improvement

Quality in the process of injection molding
A more effective mold temperature control
system saves time and costs in the process of
injection molding
Quality of injection molded parts is improved by
better control of the injection molding process.
Warping and sink marks are minimized by
evenly cooling out the plastic melt thus
minimizing internal stress. Scrap rates are
reduced or eliminated. Avoiding internal stresses
helps to produce better parts with the same
amount of required material. Certain geometries
are only possible to manufacture at required
quality standards with conformal cooling.
Even combined systems with separated cooling and heating
channels are possible or the split between main systems (for the
control of the global temperature) and specific systems (for the
handling of close to cavity critical temperatures) can be performed.
This opens up potential for
future applications.
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5.0 Supply Base

4.2 Delivery
The typical delivery time for Conformal Cooling is 10 weeks

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5.1 Supplier Information

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6.0 Technology Alternatives

Technology

Advantages

Conformal
Cooling

Huge increases in mold life

Increased dimensional accuracy of molded parts
Sink marks avoided
Easy repair of crashed cores/cavities
Conforming cooling channels demonstrate
improvements in production rate and part quality
as compared with conventional production tools.

Steel deflection during molding due to hollow

channels close to the surface
Increased difficulty in future engineering changes
with potentially fewer areas available to change
Managing the significant temperature difference
between the tool surface and molding environment

Known, proven fabrication technique

Lower cost option to laser sintering & vacuum
brazing conformal cooling channels
Easier engineering changes
Design Simplicity
Time to manufacture tool

With molds using straight line drilling methods the

distance from cavity to cooling channel differs
causing uneven heat dissipation in the material.
This results in varying temperature levels on the
cavity surface & inconsistent cooling which can
produce internal stresses and warpage.
Hot spots
Slower cycle times

Traditional
Straight Drilling
Ritemp
Cooling
System

the cooling system can be intersected by

ejector pins and screws
the cooling chamber can be high speed
machined
offers optimum gate cooling for hot runner
molds for best control and gate finish

Conformal Cooling / V1.0 / T.Pfleger

Disadvantages

Licensing fees

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7.0 Summary
Our experience shows that :

Nypros experience with conformal cooling is with creation of tooling inserts for
injection molds built by Nypromold and run in production by our plants.
Key points:

Conformal cooling can drastically reduces cycle time and improve the
quality of the injection molded part by reducing warpage and increasing
dimensional stability. This technology could be useful to all of Nypros
GBUs.

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