Conformal Cooling Channels for Improved Efficiency in Plastic Injection Mold Design - 3/23/2026

As part designs grow more complex, so too does the plastic injection mold design needed to make those parts. In a previous article, we discussed the importance of design when it comes to injection molding, and why getting the design right the first time around is so important. Today, we will examine cooling channels, a major part of any mold tooling design, and one that has a large impact on how long the overall process takes.

The Role of Cooling Channels in Plastic Injection Mold Design

Cooling channels play a crucial role in plastic injection molding. These channels are integrated throughout the mold tool in order to evenly maintain and reduce the temperature of molded plastic components at the end of the molding process. Cooling tends to be a time-consuming part of the injection molding process, and one that has received plenty of attention and innovation because of that.

Though many different methods have been developed, cooling channels offer the comparably cheapest and most efficient way to conduct the cooling process. Most commonly, these channels are drilled into the mold, with as many as possible made in order to cover as much of the part as possible without affecting tooling integrity. Drilling offers a fast and comparably cheap option to create them, but only works for straight, simple channels, a major downside especially as part geometries grow more complex.

The Innovation of Conformal Cooling Channels

Rather than move in a straight, even line, conformal cooling channels curve and conform to the part's geometry, covering a larger surface area of the part. This custom shaping of cooling channels reduces cycle times, as cooling the part becomes much easier and quicker to achieve.

Unfortunately, due to the higher initial costs of making the molds through additive manufacturing and the additional time needed to perfect the tool design, conformal cooling is not cost-effective for the majority of injection molding projects. But, for complex components and high volume projects, conformal cooling often becomes the best choice for the plastic injection mold design, especially for long-term savings.

Full Service Injection Molding Solutions from DPI

Distinctive Plastics, Inc. (DPI) offers everything from plastic injection mold design to custom tooling services to technical and highly complex injection molding solutions. If you are looking for an expert partnering in plastic injection molding and manufacturing, consider working with us! Contact us today to learn more about what DPI has to offer.