Revolutionizing Mold Making with Conformal Cooling and Digital Workflows

Metal 3D printing has emerged as a game-changing complement to traditional injection molding. By combining 3D digitizing and additive manufacturing, it’s now possible to design and produce molds with intricate conformal cooling channels—delivering better thermal performance, higher product quality, and faster cycle times.

Eplus3D offers an end-to-end solution for the mold manufacturing industry, from CAD design and simulation to high-precision 3D printing, helping customers dramatically boost productivity.

Metal 3D Printing vs. Traditional Mold Manufacturing

Traditional Cooling Channels vs. Conformal Cooling

Conventional mold production relies on drilled straight-line water channels, which are limited in geometry and typically located far from critical mold surfaces. In contrast, metal 3D printing enables the integration of complex, curved cooling channels designed to conform closely to the part geometry—significantly enhancing heat dissipation and improving production efficiency.

Key Advantages of 3D Printed Molds with Conformal Cooling:

Faster Cooling: Higher heat dissipation shortens cycle times
Improved Quality: Reduced warping and deformation
Lower Scrap Rate: More consistent cooling means fewer defects
Lightweight Design: 3D digitizing and printing enable weight reduction
Cost Efficiency: Lower material waste and mold modification costs
Bridging Molds: Easily create bridge tools based on existing molds

Digital Workflow: From CAD to Mold Delivery

1. Mold Design
   Using Siemens NX, engineers design the mold, including complex cooling channels tailored to the part’s shape.

2. Simulation
   The NX simulation module analyzes cooling performance, temperature distribution, and mold cycle behavior. Design is optimized based on the results.

3. 3D Printing
   The mold is manufactured using the EP-M250 metal 3D printer, with a build volume of 262 × 262 × 350 mm³—offering high precision for demanding applications.

4. Metallographic Analysis
   Sample parts undergo quality inspection and structural analysis to ensure they meet performance standards.

5. Post-Processing
   Heat treatment, support removal, and surface finishing are applied to prepare the mold for production.

6. Production & Delivery
   The mold is put into operation. After each plastic injection cycle, parts are removed once cooled—ensuring fast and efficient output.

Beyond Injection Molding: Versatile Applications of Metal 3D Printing

While the benefits are especially clear in injection molding, metal 3D printing is also transforming other tooling sectors such as die casting and metal stamping. Its strengths in customization, low waste, and high precision are redefining how manufacturers approach tooling and small-batch production.

Conclusion

Metal 3D printing is no longer a future promise—it’s a present-day solution to some of manufacturing’s toughest challenges. By enabling smarter design, faster iteration, and more efficient cooling, 3D printed molds are helping companies reduce costs, shorten lead times, and deliver better products.

As the industry evolves, digital workflows powered by Eplus3D are poised to play a leading role in shaping the next generation of high-performance, high-efficiency manufacturing.