Conformal cooling inserts are 3D-printed metal channels that conform to the exact geometry of the mold cavity — delivering uniform cooling where straight-drilled channels cannot reach.
Straight-drilled cooling channels are the industry default — but they are a geometric compromise that leaves significant performance on the table.
| Criterion | Conventional Channels | Conformal Cooling Inserts |
|---|---|---|
| Channel geometry | Straight (drilled only) | Follows part contour — any shape |
| Cooling uniformity | Uneven — hot spots near complex features | Uniform temperature distribution |
| Cycle time | Baseline | 20–50% shorter |
| Warpage & shrinkage | Higher, driven by thermal gradients | Significantly reduced |
| Surface defects | Sink marks, weld lines at hot spots | Reduced or eliminated |
| Part ejection | Often delayed by uneven cooling | Consistent, faster ejection |
| Manufacturing method | CNC drilling | Metal AM (DMLS/SLM) + post-process |
| Design freedom | Severely constrained | Unrestricted geometry |
We don't sell standard inserts — we engineer bespoke conformal cooling solutions adapted to your part geometry, production volume, material, and machine parameters.
Our design workflow is iterative and simulation-driven: we start with your existing mold data, identify the thermal bottlenecks, and develop a channel network that delivers the maximum thermal efficiency achievable within your tooling constraints.
Tools: Autodesk Moldflow, ANSYS Fluent / CFD, Siemens NX, Creo, Catia. Full interoperability with Tier1 and OEM tooling environments.
Our R&D pipeline transforms field experience and engineering insight into proprietary processes, IP, and new capability — ensuring Conforma's technical lead widens as the market grows.
We partner with academic researchers and run applied R&D programmes in coating, AFM post-processing, and channel flow optimisation. Ideas that pass validation become part of our service offering.
R&D is housed under the conforma.tech entity — protecting IP while enabling external collaboration and patent filing.
We are not a mail-order insert supplier. Every project includes engineering consultation, on-site commissioning, and performance follow-up — because the value of conformal cooling is only realised when the process is correctly implemented.
CONFORMA.ONE is our modular service platform — structured as CC Sales and CC Onsite modules, enabling transparent pricing and scope for each engagement.
Delivered via conforma.one — our modular service platform with defined scope, pricing, and SLA for each engagement type.
Send us your mold data and we'll run a no-cost pre-analysis. No commitment required at this stage.