Conformal Cooling Inserts

From Metal 3D Printing to Finished Mold Insert — In-House, 7-Day Delivery

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72%
Max cooling time reduction
73%
Max output increase
13+
Documented case studies
3
SLM + injection molding machines
24h
Quote turnaround
Our Approach

Three-Layer Quality Solution for Injection Molding

Most mold quality problems are attacked at the wrong stage. We solve them at all three stages — before, during, and after molding.

Layer 1 — Upstream

Conformal Cooling Inserts

3D-printed mold inserts with channels that follow part geometry. Eliminate hot spots, gate burn marks, and warpage at the source — before they happen.

Up to −72%
cooling time reduction
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Layer 2 — In-Process

In-Mold Monitoring

Real-time cavity monitoring detects abnormal shots before they reach the next stage. Catch short shots, flash, and sticking automatically — no operator needed.

100%
shots monitored per cycle
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Layer 3 — Downstream

CCD Vision Inspection

Automated optical inspection sorts good parts from defective ones at line speed. Replaces manual visual inspection — faster, more consistent, fully documented.

< 0.1s
per-part inspection time
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What We Do

Full-Service Manufacturing — Design to Finished Product

Metal 3D printing, conformal cooling mold inserts, CNC / EDM / WEDM machining, vision inspection systems, and injection molding production. Prototype samples or full production runs — all in one factory.

Conformal Cooling Inserts

3D-printed mold inserts with cooling channels that follow your part geometry. Up to 72% faster cycles, gate burn marks eliminated.

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3D Printed Mold Inserts

Injection mold cores, cavities, slides, and sprue bushings in tool steel. Up to 55 HRC. SPI-A1 capable for transparent products.

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Metal & Plastic 3D Printing

Metal SLM/DMLS/LPBF in 420 steel, 18Ni300, and more. Plus plastic 3D printing for functional prototypes and product models. Design → print → finish → ship.

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Rapid Tooling Service

3D printed dies and inserts for injection molding and die casting. Complex internal features impossible with conventional machining.

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Rapid Prototyping & Production

Metal or plastic — from a single prototype sample (打板) to full production runs (大货). One factory handles it all: 3D printing, injection molding, CNC machined metal parts.

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Low-Volume & Mass Production

Plastic injection molding for consumer and industrial parts. CNC machining centers for metal components. No minimum order. Scale from samples to mass production.

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CNC / EDM / WEDM / Injection Molding

Complete in-house manufacturing — CNC milling, sinker EDM, wire-cut EDM, plastic injection molding, and metal machining. Prototype samples to full production runs.

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CCD Vision Inspection & Mold Monitor

CCD camera inspection systems for pass/fail detection — free sample evaluation, custom solution design. Mold monitoring systems with large stock available for fast delivery.

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Our Facility

State-of-the-Art Metal 3D Printing Facility

3 SLM machines on-site. BLT A320 and E-Plus EP-M2. Located in Yuyao, Ningbo — China's manufacturing heartland.

Saiguang 3D Technology facility in Yuyao, Ningbo
SLM metal 3D printing laser sintering in progress BLT A320 and E-Plus EP-M2 3D printing machines on-site

Factory production floor — Yuyao, Ningbo

Metal 3D printing machines in operation

Core Strength

Conformal Cooling — The Proven Performance Advantage

When straight cooling channels can't reach the hottest areas of your mold, cycle times suffer, parts warp, and gate burn marks appear. Conformal cooling — only achievable through metal 3D printing — solves this at the source.

Cooling channels follow your exact part geometry — not just straight lines

Uniform heat extraction from all surfaces simultaneously

Eliminates gate burn marks on PETG, MS, and transparent plastics

Compatible with hot runner systems

Consistent cooling extends mold insert service life

See Full Technical Details →
Metric
Conventional
Conformal
Cooling time
21s
6s ↓72%
Mold temperature
94°C
62°C ↓34%
Gate burn marks
Yes
None ✓
Temp stability
Unstable
Stable ✓

Source: Cosmetics packaging case study. Results vary by application.

View All 13 Case Studies →
How It Works

From CAD File to Finished Metal Part

Design & DFAM Review

We review your CAD (NX / SolidWorks) and optimize for additive manufacturing. Cooling channels designed in Moldex3D simulation before printing.

Support & Slicing

Magics + BP software. Support structures designed for minimal post-processing and maximum dimensional accuracy.

Metal 3D Printing

SLM on BLT A320 and E-Plus EP-M2 machines. 420 steel, 18Ni300, MS1, or M2 — layer by layer.

Heat Treatment

Stress relief + age hardening to achieve 50–55 HRC. Support structure removal.

CNC Finishing & Polishing

Precision machining to final tolerances. Polishing up to SPI-A1 standard for transparent injection molded products.

Inspection & Shipping

Vision inspection, careful packing, global freight. Contact us on WhatsApp for lead time and shipping options.

Materials

Tool Steel Options

MaterialApplicationHardness
420 Mold SteelGeneral injection mold inserts50–52 HRC
18Ni300High-performance, long-run molds52–55 HRC
MS1Standard mold inserts50–52 HRC
M2High-wear tooling53–55 HRC

All materials meet SPI-A1 polishing standard — suitable for transparent injection molded products.

Industries

Who We Serve

Automotive Cosmetics Packaging Home Appliances Consumer Electronics Medical Devices Aerospace Die Casting Industrial Tooling
Case Studies

Real Results. Real Data.

Every number below comes from a documented customer project — before and after conformal cooling.

Cosmetics Packaging
Transparent PETG Bottle Cap
72%
Faster cooling
0
Gate burn marks

21s → 6s cooling time. Part temp: 93°C → 60°C. Gate burn marks eliminated.

Home Appliances
Xiaomi Humidifier
+50%
Output increase
33%
Faster cooling

880 → 1,320 pcs/day. Mold temp: 62°C → 48°C. Unit cost: ¥13.6 → ¥10.

Medical Devices
Medical Deep-Hole Plate
+73%
Output increase
43%
Faster cooling

1,760 → 3,046 pcs/day. 45s → 26s cooling. Unit cost: ¥3.50 → ¥2.60.

View All 13 Case Studies →

Trusted by Leading Manufacturers

FAQ

Frequently Asked Questions

What is conformal cooling and how does it reduce cycle time?

Conformal cooling uses 3D-printed cooling channels that follow the exact geometry of your mold cavity. Unlike conventional straight-drilled channels, this enables uniform heat extraction from all surfaces simultaneously — reducing cooling time by up to 72%. For example, a PETG bottle cap mold went from 21s to 6s cooling, and a Xiaomi humidifier mold increased output from 880 to 1,320 pieces/day.

What materials do you use for 3D printed mold inserts?

We use 420 Mold Steel and 18Ni300 (Maraging Steel) for SLM-printed mold inserts. After heat treatment, parts achieve 50–55 HRC hardness. Surface finish can reach SPI-A1 (mirror polish), suitable for transparent products like PETG and PMMA.

How long does delivery take to Europe or the US?

Production takes 7–14 working days. We ship worldwide via DHL Express (3–5 days to Europe/US), FedEx, or sea freight. Total turnaround is typically 2–3 weeks from order to delivery.

How much cheaper is Saiguang compared to European services?

Our prices are typically 50–70% lower than European metal 3D printing services. A conformal cooling insert costing €3,000–8,000 in Germany typically costs €800–2,500 with us, using equivalent materials and quality standards.

What machines does Saiguang operate?

We operate 3 SLM machines (BLT A320 and E-Plus EP-M2), plus CNC milling centers, sinker EDM, wire-cut EDM, and injection molding machines. Our facility in Yuyao, Ningbo employs 35 people.

Do you offer CNC machining and injection molding?

Yes — we are a full-service manufacturer. CNC milling, sinker EDM, wire-cut EDM, and plastic injection molding, all in-house. From prototype samples to full production runs, metal and plastic parts, no subcontracting.

Engineering Blog

Learn Before You Buy

In-depth technical guides written by our engineering team — so you understand exactly what you're getting and why it works.

BEGINNER GUIDE

What Is Conformal Cooling?

How conformal channels outperform conventional cooling, which applications benefit most, and what cycle time reduction to realistically expect.

Read Guide →
ENGINEERING GUIDE

Conformal Cooling Channel Design

D/W/P/R parameter rules, channel geometry types, Reynolds number targets, and the 12-point pre-print checklist every insert needs before going into production.

Read Guide →
ROI ANALYSIS

Conformal Cooling in Injection Molding

Real cycle time data across automotive, electronics, and medical applications — with ROI payback calculations at different production volumes.

Read Guide →
View All 12 Engineering Guides →

Ready to Cut Your Cycle Time?

Send us your part drawing or describe your current cooling issue. We'll analyze your mold and respond within 24 hours.

+86 182 6866 1068

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