Case Study: Portland State University achieves conformal cooling channel development breakthroughs with SolidWorks

Rapidmade/portland State University Advancing Injection-mold Technology Research With Solidworks Solutions

Portland State University partnered with RapidMade to tackle the long-standing challenge of bringing conformal cooling channels to injection molding—geometries that traditional milling and drilling cannot produce. To support federally funded research, the PSU team used SolidWorks solutions, including SolidWorks Professional, SolidWorks Simulation Premium, SolidWorks Flow Simulation, and SolidWorks Plastics Premium, as an integrated platform for designing, simulating, and preparing mold cores for additive manufacturing.

Using SolidWorks, the team implemented a workflow automation path that combined CAD, injection-molding, CFD, and thermal simulation to design and optimize conformal cooling channels for 3D‑printed metal molds. The work secured federal research funding, created an automation process for conformal cooling development, validated additive manufacturing approaches for mold cores, and laid the groundwork for improved part quality, faster cycle times, and reduced scrap and energy use.

Portland State University

Christopher Mullens

PSU Student and Team Lead