Every Conforma engagement follows the same structured process — from the first data review to long-term performance follow-up. No shortcuts, no scope ambiguity.
We begin every project with a thorough review of your existing mold design, production data, and quality complaints. No assumptions — only data.
Our engineers analyse the mold geometry, cooling channel layout, and thermal history to identify where heat is accumulating, which features are limiting cycle time, and whether a conformal cooling insert retrofit is feasible and warranted.
Timeline: 3–5 business days from mold data receipt. No cost to qualifying pilot partners.
We design and simulate the proposed conformal cooling channel geometry before a single gram of metal is printed. The simulation loop runs until the design meets the target thermal performance.
Our team uses Autodesk Moldflow for injection moulding simulation and ANSYS Fluent / CFD for channel flow and thermal analysis. The result is a validated cooling design with predicted cycle time, cavity temperature distribution, and warpage — not an estimate.
Tools: Autodesk Moldflow, ANSYS Fluent, Siemens NX. Full interoperability with customer CAD environments.
Simulation data is translated into financial terms — specific to your production volume, machine rate, energy cost, and scrap profile. Decision-makers get the numbers they need.
We calculate expected annual savings from cycle time reduction, energy efficiency, and scrap rate improvement. Payback period is modelled against the total investment in the CC insert — including design, production, and commissioning cost.
For automotive applications, mold tooling changes require OEM approval. We prepare the complete technical documentation package and support the Tier1 and OEM engineering teams through the approval process.
Our team (with 26+ years of Ford Otosan and OEM tooling experience) understands approval protocols, quality documentation requirements, and the engineering language that OEM quality and tool engineering teams respond to.
Advantage: Our team spent 26 years inside Ford Otosan's tool engineering organisation — we know the approval process from the inside.
We coordinate the mold modification plan with the Tier1 toolmaker — defining the insert pocket geometry, water connection interface, and any required modifications to the existing mold base.
This phase is managed by Gürkan Erol, whose 26-year career at Ford Otosan was spent in tool & die production leadership and mold engineering. No interpretation gap between design intent and shop floor execution.
The conformal cooling insert is manufactured using metal additive manufacturing (DMLS/SLM) by our partner ADDPARK — EMEA's most experienced AM engineering bureau for tooling applications.
Post-processing is handled by Beta Kesici Takım: CNC finish machining to ±0.01mm tolerances, EDM for cavity surfaces, heat treatment for hardness and residual stress relief, and polishing or coating as specified.
Capacity: Build volume up to 500×500×400mm. Lead time 3–5 weeks from design freeze depending on part complexity.
Our engineers install and commission the insert at your production facility, run trial shots, optimise machine parameters, and document actual vs. simulated performance.
Commissioning is not the end of the engagement — it's the start of the performance tracking phase. We collect production data, verify cycle time reduction, and provide ongoing technical support for the duration of the agreed follow-up period.
Accountability: We stand behind our simulation predictions. If performance doesn't match the model, we investigate and resolve at no extra cost.
The pre-analysis (Step 01) is free for qualifying pilot partners. Send us your mold data and we'll turn it around in 3–5 business days.