A Review on Injection Molding: Conformal Cooling Channels, Modelling, Surrogate Models and Multi-Objective Optimization

Plastic injection molding is a fundamental manufacturing process used in various industries, accounting for approximately 30% of the global plastic product market. A significant challenge of this process lies in the need to employ sophisticated computational techniques to optimize the various phases. This review examines the optimization methodologies in injection molding, with a focus on integrating advanced modeling, surrogate models, and multi-objective optimization techniques to enhance efficiency, quality, and sustainability. Key phases such as plasticizing, filling, packing, cooling, and ejection are analyzed, each presenting unique optimization challenges. The review emphasizes the importance of cooling, which accounts for 50–80% of the cycle time, and examines innovative strategies, such as conformal cooling channels (CCCs), to enhance uniformity and minimize defects. Various computational tools, including Moldex3D and Autodesk Moldflow, are discussed due to their role in process simulation and optimization. Additionally, optimization algorithms such as evolutionary algorithms, simulated annealing, and multi-objective optimization methods are explored. The integration of surrogate models, such as Kriging, response surface methodology, and artificial neural networks, has shown promise in addressing computational cost challenges. Future directions emphasize the need for adaptive machine learning and artificial intelligence techniques to optimize molds in real time, offering more innovative and sustainable manufacturing solutions. This review is a comprehensive guide for researchers and practitioners, bridging theoretical advancements with practical implementation in injection molding optimization.