Conformal Cooling Channels in Injection Molding and Heat Transfer Performance Analysis Through CFD—A Review

Gabriel Wagner () and João M. Nóbrega ()
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Gabriel Wagner: Institute for Polymers and Composites—IPC, University of Minho, 4800-058 Guimarães, Portugal
João M. Nóbrega: Institute for Polymers and Composites—IPC, University of Minho, 4800-058 Guimarães, Portugal

Energies, 2025, vol. 18, issue 8, 1-39

Abstract: The use of conformal cooling channels (CCC) in the injection molding process has revolutionized the polymer industry by enhancing part cooling uniformity and improving cooling efficiency, minimizing undesired defects such as warpage and shrinkage inherent to the process. This review paper provides a detailed investigation of the literature on CCC, with special focus on how computational fluid dynamics (CFD) has been employed to analyze and optimize the thermal performance of the cooling system. Additionally, key aspects of CCC design, including geometry optimization, surface roughness, and flow dynamics, are evaluated to improve cooling efficiency, reduce cycle time, and enhance product quality. Several CFD-based studies are reviewed to highlight commonly used simulation methods and CCC optimization approaches for heat transfer enhancement. Particular attention is given to how simulation tools contribute to design improvement and decision-making, addressing practical constraints related to thermal behavior and manufacturability. Key performance parameters such as pressure drop, temperature uniformity, cooling time, and manufacturing limitations are examined and compared, offering a foundation for future directions to advance CCC design and CFD analysis to optimize injection molding. Aiming at contributing to the academia and the industry, the novelty of this review paper lies in its integrative perspective, providing a comprehensive analysis of coupling designing tasks with CFD simulations. As a result, this paper serves as a valuable resource for researchers and industry professionals aiming to leverage CFD for the development of high-performance, energy-efficient CCC.

Keywords: injection molding; conformal cooling channels; heat transfer; computational fluid dynamics; cooling systems (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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