Optimizing Plastic Injection Molding with Advanced Cooling Strategies: an Experimental Study of SimForm and PulseCooling Approaches

Efficient thermal management is critical in plastic injection molding to optimize cycle times, part quality, and energy consumption. This study presents an experimental evaluation of two advanced technologies: SimForm by Maya HTT, a cloud-based injection molding process simulation platform with generative design for cooling channel placement, and PulseCooling by CITO, a system that uses precision in-mold temperature sensors to dynamically regulate coolant flow and maintain optimal mold surface temperatures. The project targeted cooling challenges in manufacturing thick-walled snap-lid plastic parts. A 3D-printed mold insert with conformal cooling channels was developed using SimForm's generative design capabilities, and four scenarios were tested: conventional cooling, conformal cooling, each with and without PulseCooling. Mold surface temperatures were measured and correlated with SimForm simulation results, validating the simulation models against real-world mold trials. SimForm's simulation-driven design enabled the selection of effective cooling strategies, while PulseCooling technology demonstrated precise thermal control. With validated models, it is possible to recommend optimal cooling line set points, resulting in reduced cycle times and lower energy consumption. This work highlights the benefits of integrating simulation-driven design and innovative cooling technologies in injection molding. The findings suggest that adopting solutions like SimForm and PulseCooling can set new standards for productivity and sustainability in mold cooling.