Cooler molds. Faster cycles.
DMLS-printed inserts with internal water channels engineered to match your mold geometry. Documented −17% to −55% cycle-time reductions — deployed across plastic packaging, medical, automotive, white-goods, and defense production.
We design, simulate, print, and finish a single-piece insert that drops into your existing mold pocket. Lead time 3–5 weeks from your CAD or sample part.
Channels that
follow the part.
Traditional drilled cooling can only run in straight lines, missing the contour of every cavity. Conformal cooling traces your part geometry — channels run 3–8 mm beneath the surface, close enough to actually remove heat where it builds up.
That's only possible with additive manufacturing — the entire insert is built layer by layer, channels included, in a single piece of maraging steel.
One piece.
No joints, no leaks.
Every Conforma insert is additively built as a single body. The conformal channels are part of the same printed structure as the cavity wall — no welds, no fittings, no thermal interfaces between cooling and surface.
- Cavity face — mirror-polished
- Conformal channels — serpentine, ⌀ 3–8 mm
- Water ports — threaded, in/out
- Mounting bolts — M6 × 4 corners
- Ejector pin clearances
Drops into
your existing mold.
We design every insert to your existing mold base — mounting pattern, water connection, ejector layout. From your CAD or sample part to a finished, water-tested insert in 3–5 weeks.
No retooling. No mold redesign. No production downtime beyond a single insert swap.
Why drilled lines
leave performance behind.
Straight lines only
FIG.A · Milled groove
- Can only follow straight bores or flat-face grooves
- Misses every curved cavity surface — uneven gap
- Hot spots → warpage, sink marks, longer cycles
- Limited to ~30–50% of theoretical cooling potential
Follows the cavity
FIG.B · Conformal manifold
- Channels trace the cavity contour at constant 1.5–5 mm depth
- Equal heat removal across the whole surface
- Faster, more consistent cycles — measurably less warpage
- −17% to −55% cycle time in published studies (Renishaw, EOS, Magna)
From your part
to your mold.
Engineering
specifications.
| Materials | Maraging 1.2709 · H13 tool steel · BeCu (on request) |
| Cavity tolerance | ±0.05 mm finished, ±0.10 mm overall geometry |
| Channel diameter | 3–8 mm, designed per thermal load |
| Insert envelope | 30×30×20 mm to 250×250×150 mm |
| Surface finish | Cavity face polished to Ra 0.4 µm · backing faces matte as-printed |
| Cooling capacity | 50–62% improvement over equivalent drilled-channel insert |
| Cycle life | Production-grade — same as machined hardened tool steel |
| Typical lead time | 3–5 weeks from approved design to delivered insert |
Bring us your mold.
Send the part geometry or a sample. We'll engineer the cooling solution, simulate it, and quote the path to a finished insert.