22/09/2026
🌎 Minnotec (Thailand) Co., Ltd. 🌍
🔍 From Simulation to Real-World Validation: Verify Conformal Cooling Performance Before Production
Designing Conformal Cooling Channels using Additive Manufacturing or 3D Printing allows cooling channels to follow the geometry of the molded part more closely than conventional cooling systems. However, for complex molds with high development costs, one critical question remains:
How can we ensure that simulation results accurately reflect the actual behavior of the mold?
In this case study, Moldex3D was used to simulate the temperature distribution and flow performance of a conformal cooling system. The results were then validated under identical conditions using a thermographic camera and pressure/flow meter, confirming the simulation accuracy before implementing the design in actual production.
🔬 Simulation vs. Actual Test
The results demonstrated a strong correlation between the simulation and actual testing.
💧 Simulated flow rate: 3.97 L/min
💧 Measured flow rate: 3.80 L/min
🌡️ The temperature distribution predicted by Moldex3D also showed a similar trend to the measurements captured by the thermographic camera. At the final stage of the test, the temperature difference between the simulation and experiment was approximately 1.3°C.
These results demonstrate how Moldex3D can be used to evaluate the temperature field and flow field of conformal cooling systems before actual mold production.
⚙️ From Beryllium Copper to Stainless Steel
The original design used Beryllium Copper (BeCu), which provides high thermal conductivity but has limitations in wear resistance, particularly when molding materials containing glass fiber.
The team therefore developed a new insert using 3D printing and high-hardness stainless steel, combined with a conformal cooling design to compensate for the lower thermal conductivity of stainless steel compared with BeCu.
Testing showed that the stainless steel design could maintain the same cooling performance within the same cycle time, while providing a more uniform mold temperature distribution. This also helps reduce the risk of warpage caused by mold temperature differences.
📊 Key Results
✓ Simulation results closely matched the actual test results
✓ Mold lifespan doubled
✓ Mold manufacturing costs were reduced by 50% compared with the original Beryllium Copper mold
✓ More uniform mold temperature distribution
✓ Reduced risks and potential errors before actual mold production
✓ Improved efficiency in the development of complex molds
💡 Simulation is not only about “prediction” — it can also provide valuable engineering data to “validate the design” before investing in actual production.
With Moldex3D, engineers can evaluate design concepts, compare alternatives, and verify cooling system performance before manufacturing begins — helping reduce development time, trial-and-error, and development costs, especially for complex mold applications.
🚀 From Simulation to Real Results.
Design Smarter. Manufacture Better with Moldex3D.
📩 Interested in learning more about Moldex3D, Conformal Cooling Simulation, and Mold Design Optimization?
Contact Minnotec (Thailand) Co., Ltd. for more information.
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