<p>Silicon rubber rapid tooling is important because it provides a cost-effective and time-efficient method for producing small batches of prototype or low-volume production parts. In injection molding, efficient cooling is crucial, making conformal cooling channels (CCCs) a common choice in precision machining operations. However, using acetone solutions to remove polyvinyl butyral (PVB) CCCs from silicon rubber rapid toolings raises concerns regarding operator safety, environmental pollution, and the unsustainable nature of acetone-based practices. To align with green manufacturing principles and contribute to sustainable development goals (SDGs), ethanol was adopted as a substitute for acetone, offering advantages such as lower volatility, ecological compatibility, and reduced harm to human health. While this substitution represents a step toward environmentally friendly manufacturing, the traditional approach to eliminating PVB CCCs heavily relies on energy-intensive, laboratory-based testing and experimentation, conflicting with energy-saving and carbon-reduction objectives central to sustainable production goals. To address these challenges and enhance process sustainability, this study introduces a simplified and energy-efficient method designed to improve the removal of PVB CCCs from silicon rubber rapid toolings. By reducing resource consumption, lowering energy requirements, and promoting eco-friendly practices, the proposed hybrid method aligns with both green manufacturing strategies and the broader objectives of energy saving and carbon reduction. The findings demonstrate that the hybrid method reduces the removal time by 88.2&#xa0;min, resulting in a 72.77% reduction in time. This innovative approach not only advances the sustainability of tool preparation but also supports global SDGs, fostering the adoption of sustainable and energy-efficient practices in injection molding operations.</p>