Conformal Cooling Solutions Process

  The patented process developed by Conformal Cooling Solutions Ltd., utilizes an additive manufacturing process to incorporate cooling channels that closely follow the mold face contours, typically within 5/8" from part surface

  The CCS developed channel is machined into the face during the roughing stage and our automated system will bridge the channel gap forming a cavity able to carry a large volume of cooling water. The CCS cell utilizes technology which has a proven track record of over 30 years of additive manufacturing perfected for the aerospace industry

  The process produces a part surface which has same or better parent material properties and strength. Unlike sintered powdered metal inserts, the deposited material is non-porous, and can tolerate much larger cooling passages. The process can also deposit material up to 2.5 lbs/hour for faster turnaround times

Patented conformal cooling channel developed by CCS showing the additive layers which bridge the opening. The patented process allows this to be completed by machine or manually if needed

Advantages of the CCS Process:

  • Channel cross section is much larger than conventional gun drilled holes allowing it to carry greater volumes of water

  • Channel shape and size reduce water pressure up to 20X less than conventional holes thus reducing the required pump head pressure

  • Bead profile and channel shape help contribute to turbulence and aids with energy transfer

  • The process maintains constant part surface to water distance to minimize distortion during cooling

  • No baffles, bubbler systems and freeze plugs are required which reduces manufacturing costs

  • Drastic reduction in the number of drilled passages helps reduce build costs

  • Allows more space and freedom to place slides and lifters where they can help assist the de-molding process

  • Ability to cool difficult to access features including slides and around injection nozzles for faster freeze off

Comparison of a conventionally cooled mold on the left versus a CCS conformal cooled mold on the right. Note the long cooling channels across the faces and the amount of available space for additional slides and lifters

Applying our Process

Conformal Cooling Solutions utilizes a patented automated process to perform the additive proceedure to mold and die surfaces. It can be performed manually where the part geometry does not allow access for the torch assembly.

Typical Steps:

  • Engineering study is performed at the design stage to determine placement of conformal channels and results calculated by programs such as MoldFlow analysis

  • Channels are machined into the part using the new math data during the block roughing stage

  • CCS developed software is able to read the data of the paths and determine the correct offsets and build up required. This data is then communicated with the robotic cell

  • Tool is placed on a multi axis table with pre-heating ability and brought to temperature

  • The cell applies the additive build up with beads placed in a sequence to minimize distortion of the channel and mold face. Material characteristics of the beads are the same or better than parent material

  • If the geometry does not allow access to the tool, it can also be added manually

  • Once complete, the part is heat treat normalized and can be sent for finish machining and polishing