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<p>In the injection molding process, cooling efficiency and uniformity significantly influence product quality and cycle time. This paper presents a multi-objective optimization study aiming to minimize both molding time and maximum warpage through process parameter tuning, while comparing the performance of traditional and conformal cooling systems. Using Latin Hypercube Sampling, 15 process parameter sets were simulated in Moldflow. A radial basis function neural network was trained to model the relationship between process parameters and quality objectives, followed by particle swarm optimization to obtain Pareto fronts for both cooling systems. Experimental validation confirmed simulation accuracy with errors below 5%. The results show that through optimized process parameters, conformal cooling achieved a trade-off between warpage and molding time in the ranges of approximately 0.25 ~ 0.51&#xa0;mm and 12.9 ~ 15.8&#xa0;s, respectively. Compared to traditional cooling, the conformal system reduced maximum warpage by about 25% and molding time by 30% on average, thereby shortening the molding cycle and improving efficiency while enhancing product quality.</p>

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A comparative study of conformal and traditional cooling system for optimizing molding time and warpage reduction

  • 期刊论文

  • 发表日期：

    2026年1月20日

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  • Junhui Liu,
  • Liping Luo,
  • Xiaojie Feng,
  • Junwu Luo

摘要

In the injection molding process, cooling efficiency and uniformity significantly influence product quality and cycle time. This paper presents a multi-objective optimization study aiming to minimize both molding time and maximum warpage through process parameter tuning, while comparing the performance of traditional and conformal cooling systems. Using Latin Hypercube Sampling, 15 process parameter sets were simulated in Moldflow. A radial basis function neural network was trained to model the relationship between process parameters and quality objectives, followed by particle swarm optimization to obtain Pareto fronts for both cooling systems. Experimental validation confirmed simulation accuracy with errors below 5%. The results show that through optimized process parameters, conformal cooling achieved a trade-off between warpage and molding time in the ranges of approximately 0.25 ~ 0.51 mm and 12.9 ~ 15.8 s, respectively. Compared to traditional cooling, the conformal system reduced maximum warpage by about 25% and molding time by 30% on average, thereby shortening the molding cycle and improving efficiency while enhancing product quality.