+

HYDROPLEX: WATER BOTTLE MOLD DESIGN

WITH CONFORMAL COOLING CHANNEL

A PROJECT REPORT

Submitted by

YOGESHWARAN T - 2021119033
SIVAMARIMUTHU S - 2021119304
DHANUSH N - 2021119308
BACHELOR OF ENGINEERING

IN

SIXTH SEMESTER

PRINTING AND PACKAGING TECHNOLOGY

COLLEGE OF ENGINEERING GUINDY, CHENNAI-600025

ANNA UNIVERSITY: CHENNAI 600025

MAY -2023

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 BONAFIDE CERTIFICATE

Certified that this project "HYDROPLEX: WATER BOTTLE MOLD DESIGN

WITH CONFORMAL COOLING CHANNEL" is the Bonafide work of
YOGESHWARAN T (2021119033), SIVAMARIMUTHU S (2021119304),
DHANUSH N (2021119308) who carried out the project work under any supervision.

SIGNATURE. SIGNATURE.
HEAD OF THE DEPARTMENT, Dr. SANDEEP J,
Dept. of Printing and Packaging SUPERVISOR,
technology Assistant Professor,
College of Engineering-Guindy, Dept. of Printing and Packaging
Anna University, technology
Chennai-600020. College of Engineering-Guindy,
Anna University,
Chennai-600020.

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

We sincerely thank to Tamil Nadu Skill Development Corporation (TNSDC),

“Naan Mudhalvan” Platform and Tamil Nadu Centre of Excellence for Advanced
Manufacturing (TANCAM) for encouragement towards our project work for providing
necessary skill training.

We sincerely thank our dean Dr. L. SUGANTHI M.B.A, Ph.D., for encouragement
towards our project works.

We also thank our Head of the Department and our project guide and our parents
for the complete and wholehearted support, motivation guidance and help in making our
project activities.

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 ABSTRACT

The 3DEXPERIENCE platform is being utilized in a project aimed at enhancing

the structural design of water bottle moulds. The project aims to improve efficiency and
durability, pushing the boundaries of traditional mould design paradigms. The project
involves a thorough investigation of structural requirements and material attributes, using
powerful simulation tools to conduct finite element analysis (FEA) to evaluate stress
distribution, deformation patterns, and potential failure mechanisms. The strategy is based
on lightweight yet sturdy mould structures, achieved through repeated optimization
methods. Parametric modelling tools are used to fine-tune geometries to find the best
balance between weight reduction and structural integrity. The methodology also includes
research of innovative materials and production processes, focusing on sustainability. Key
areas of investigation include lattice structures, topology optimisation, and sophisticated
material simulations. The goal is to create a water bottle mould design that exceeds
performance expectations while incorporating efficiency and sustainability principles.
This project represents a significant advancement in product design engineering and
modelling, paving the way for a future where efficiency, durability, and sustainability
coexist peacefully in product design.

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 TABLE OF CONTENT

CHAPTER NO TITLE PAGE NO

ABSTRACT iv

LIST OF FIGURES vi

INTRODUCTION 1
1
1.1 2
AN OVERVIEW OF 3DEXPERIENCE - CATIA DESIGN
SOFTWARE
1.1.1 2
AN END-TO-END PROCESS FOR MECHANICAL &
SHAPE DESIGN
1.1.2 2
REAL-TIME COLLABORATION
1.1.3 WHY CHOOSE 3DEXPERIENCE CATIA? 3
1.2 3
TOOLBARS
1.2.1 4
SKETCHER WORK BENCH TOOL BARS
1.2.2 4
THE OPERATION TOOL BAR

1.2.3 THE CONSTRAINTS TOOL BAR 5

1.2.4 SPECIFYING THE WORK PLANE 5
1.2.5 MODIFYING THE PROFILE USING CHAMFER 6
1.3 CONSTRAINT 7
1.4 LITERATURE SURVEY 9
HYDROPLEX: WATER BOTTLE MOLD DESIGN WITH 10
1.5 CONFORMAL COOLING CHANNEL

1.5.1 SCOPE OF THE PROJECT 10

1.5.2 EXISTING DESIGN OF MOLD 12
1.5.3 MATERIAL SELECTION 14
1.5.4 MODIFIED DESIGN OF MOLD 15
1.5.5 MASS PRODUCTION 18
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1.6 FUTURE SCOPE OF THE PROJECT 18
1.7 CONCLUSION 22

1.8 REFERENCE 24

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 LIST OF FIGURES

S.NO. LIST OF FIGURES PAGE NO.

1.1 Toolbar 4

1.2 Profile Tool Bar 4

1.3 Constraints Tool Bar 5

1.4 Specifying the Work Plane 5

1.5 Chamfer Tool 6

1.6 Sketch Constraining 7

1.7 Existing design of Mold 12

1.8 Modified design of Mold 15

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 INTRODUCTION

The Naan Mudhalvan Course: PRODUCT DESIGN AND

MANUFACTURING 3D SURFACE MODELLING teaches students how to create
models of engineering objects and assemblies using the 3DEXPERIENCE - CATIA
software. This software is widely used in various interdisciplinary engineering fields
for modeling and is the primary tool used in this course. Through the course, students
gain a comprehensive understanding of the software's capabilities and learn how to use
it to complete various modeling tasks. By the end of the course, students are equipped
with the knowledge and skills needed to create high-quality engineering models and
assemblies using 3DEXPERIENCE - CATIA, making them well-prepared for a career
in the mechanical engineering industry.

3DEXPERIENCE - CATIA is designed to help engineering companies achieve

engineering excellence. The software boasts a powerful set of social and collaborative
3D modelling and simulation tools that enable users to work together on design
projects and improve their overall engineering capabilities. With CATIA, engineering
companies can streamline their design processes and reduce the time and resources
required to bring their products to market. Whether it's creating 3D models or running
simulations, CATIA's suite of tools provides the necessary support for engineering
teams to achieve their goals.

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 1.1 AN OVERVIEW OF 3DEXPERIENCE - CATIA DESIGN SOFTWARE

1.1.1 An End-to-end process for mechanical & shape design

3DEXPERIENCE CATIA is a software solution that offers its users unlimited

possibilities to create anything they want. Its geometrical modeler is specifically
designed to support the completion of highly complex mechanical products and parts
with great accuracy, from concept to detailing. The software provides a comprehensive
set of tools, including high-quality surface and part design, assembly creation,
mechanism motion, 3D mock-up review, and drawing generation, ensuring that users
have all the necessary support to achieve their design goals. Additionally,
3DEXPERIENCE CATIA guarantees users the best geometry accuracy for part and
tooling surfaces, as well as the highest level of performance, even when working on
very heavy models with thousands of features or parts. Overall, 3DEXPERIENCE
CATIA is a powerful and versatile tool for creating complex designs with precision
and ease.

1.1.2 Real-time collaboration

Effective collaboration is vital for every team, and 3DEXPERIENCE CATIA offers
a powerful database platform that enables colleagues, suppliers, and external partners to
work together more efficiently and seamlessly. This results in shorter cycle times and
fewer late changes, which can help streamline the design process. With 3DEXPERIENCE
CATIA, users can access and share the latest version of their data, allowing different
stakeholders to work in parallel on the same project and save their modifications
simultaneously. If necessary, different stakeholders can have different access rights to the

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data, depending on their role. For example, reviewers or providers can see only the parts
they need for their work and not the overall product, and they can have different levels of
access rights, such as read or modify. Managing all access rights is easy with the platform,
and adding external team members later is also straightforward thanks to the platform's
simple user and license management system. Overall, 3DEXPERIENCE CATIA offers an
efficient and collaborative environment for teams to work together and achieve their
design goals.

1.1.3 Why choose 3DEXPERIENCE CATIA?

3DEXPERIENCE CATIA is a software solution that offers a great user experience

with its intuitive user interface and simple design tasks. Users can make selections
in 3D and receive user guidance, making the software easy to use for both casual
and expert users. The software also has advanced modeling capabilities and
provides fast and high-quality display, enabling users to work with ease and
efficiency. In addition, 3DEXPERIENCE CATIA is very quick to learn and master
for existing CATIA V5 users, making the transition process smoother. Users of all
types can benefit from the software, with casual users finding it easy to use, expert
users being very productive, and existing CATIA V5 users experiencing higher
productivity in solid and surface modeling. The software also offers optional easy
UI customization for further convenience. Overall, 3DEXPERIENCE CATIA
provides a great user experience that enhances productivity and supports users of
all levels.
1.2 TOOL BARS

Many standard toolbars are used in the different modes like sketcher mode
operational mode etc, In 3DEXPERIENCE CATIA software. Here we discuss the
tool bars used in sketcher with some examples.
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1.2.1 Sketcher Work Bench Tool Bars

There are three standard tool bars found in the Sketcher Work Bench.
The three tool bars are shown below. The individual tools found in each of the
three tools are labeled to the right of the tool icon. Some tools have an arrow
located at the bottom right of the tool icon. The arrow is an indication that there is
more than one variation of that particular type of tool. The tools that have more
than one option are listed to the right of the default tool. To display the other tool
options, you must

select and hold the left mouse button on the arrow as shown in

Figure1.1 TOOLBAR

1.2.2 THE OPERATION TOOL BAR

• Profile Tool Bar

Figure 1.2 Profile Tool Bar

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1.2.3 THE CONSTRAINTS TOOL BAR

Figure1.3 Constraints Tool Bar

1.2.4 SPECIFYING THE WORK PLANE

The next step is to create a 2-dimensional profile of the part. The
Sketcher Work Bench is a two-dimensional (planar) work area. To use the
Sketcher Work Bench, you must specify which plane the profile is to be created
on. Specifying, the plane can be done several different ways.
ZX plane

Figure 1.4 Specifying the Work Plane

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1.2.5 MODIFYING THE PROFILE USING CHAMFER

The Chamfer icon is also located in the Operations tool bar. This procedure
assumes you know what a chamfer is. The steps required to create a chamfer are
almost identical to creating a corner. Select the Chamfer icon.
The command prompt at the bottom left hand of the screen, will
prompt you with the following: “Select the first curve, or a common point”.
For this exercise select line 5. The next command prompt will ask you to
“Select the second curve”.

Figure 1.5 Chamfer Tool

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 1.3 Constraint

Figure 1.6 Sketch Constraining

This tool allows you to create individual constraints, one at a time. You have
already applied a constraint and may not even know it. The Anchor icon is a
constraint. The values attached to the Chamfer and Corner are constraints. To
apply Dimensional Constraints, complete the following steps:
1. Select the Constraint icon.

2. Select the line and/or Sketcher element to be constrained.

3. The Sketcher element will turn green (constraint symbol) along with the
appropriate dimension and box with the value in it. To re-locate the
constraint value, select the value box and drag the mouse to the desired
location.

4. If the initial location of the constraint is not satisfactory re-select the

dimension and drag and drop it at the new location.
5. To edit the value of the constraint double click on the value box. This will
bring up the Constraint Definition pop up window shown in. This window

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 shows the existing value forth Sketcher element. This value can be edited
by typing the new value over the existing value. Then select OK or hit the
Enter key. The entities linked to the constraint will automatically be updated
to the new value.

6. If the constraint is between two different entities, such as lines, select the
first line and then the second line. 3DEXPERIENCE CATIA will constrain
the distance between the two entities. The constraint value will appear near
the constraint. To move the constraint value. For this lesson constrain your
“L Shaped Extrusion” like the one shown in Figure

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1.4 LITERATURE SURVEY
Silva, H. M., Noversa, J. T., Fernandes, L., Rodrigues, H. L., &
Pontes, A. J. (2022). Design, simulation and optimization of conformal
cooling channels in injection molds: a review. The International Journal of
Advanced Manufacturing Technology, 120(7), 4291-4305 where they
described the process of simulation and making of conformal cooling channels
for molds in their work.
Kanbur, B. B., Suping, S., & Duan, F. (2020). Design and
optimization of conformal cooling channels for injection molding: a review.
The International Journal of Advanced Manufacturing Technology, 106(7),
3253-3271 described the optimization process and cooling effects with the
channels present in the mold.
Park, H. S., & Dang, X. P. (2012). Design and simulation-based
optimization of cooling channels for plastic injection mold. New
technologies: trends, innovations and research, 19-44 detailed about the
cooling channels need for the mold in the process of manufacturing with
injection molds.
Kamoga Mulungi, S. M. Water bottle manufacture and production
explained about the manufacturing and the production process of the water
bottles.
Syrett, D. (2006). Bottle design and manufacture and related
packaging. Carbonated Soft Drinks: Formulation and Manufacture, 181-
217 described the futuristic design structure and the manufacturing procedure of
the bottles and the packaging process in the products.
Vojnová, E. (2016). The benefits of a conforming cooling systems the
molds in injection moulding process. Procedia Engineering, 149, 535-543
researched about the benefits in conformal cooling system.

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1.5 HYDROPLEX: WATER BOTTLE MOLD DESIGN WITH
CONFORMAL COOLING CHANNEL

1.5.1 Scope of the Project

The project's goal is to use the advanced features of the 3DEXPERIENCE
platform to create an optimised water bottle mould with a major focus on
structural integrity and efficiency. It covers the complete design lifecycle, from
idea to manufacture, and uses cutting-edge tools and techniques to generate
exceptional outcomes.

Integrated Design Environment: Multidisciplinary teams may collaborate

seamlessly using 3DEXPERIENCE, assuring alignment and coherence
throughout the design process. This integrated strategy improves
communication, speeds up decision-making, and promotes creativity.

The project iteratively refines the mould design using parametric modelling and
sophisticated simulation technologies inside 3DEXPERIENCE. Parametric
characteristics help quick design iteration, while simulation capabilities allow
for full examination of structural performance under various loading
circumstances, assuring optimal design.

Topology Optimisation: Using 3DEXPERIENCE's topology optimisation tools,

the research investigates novel design options to produce mould structures that
are both sturdy and lightweight. This method reduces the amount of material
used while preserving structural integrity, resulting in designs that are more
resource-efficient and perform better.

Platform for Collaboration: 3DEXPERIENCE facilitates real-time

communication, data sharing, and version control between project stakeholders.
In addition to ensuring congruence between design aims and stakeholder
requirements, this promotes transparency and encourages the sharing of
feedback.

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Information-Based Engineering (KBE): To collect and reuse design
information, the project uses 3DEXPERIENCE to build knowledge-based
engineering approaches. The creation of design templates and guidelines
automates tedious design activities, speeding up the process and preserving
consistency between revisions.

Digital Mockup & Visualisation: Stakeholders can visualise and evaluate the
water bottle mould design in a virtual environment by utilising
3DEXPERIENCE's digital mockup and visualisation capabilities. Improved
comprehension and early feedback are made possible by high-fidelity rendering
and virtual reality capabilities, which improve design results.

Lifecycle Management: Throughout the product lifecycle, 3DEXPERIENCE's

lifecycle management features allow you to keep track of design iterations,
revisions, and documentation. This guarantees configuration management,
traceability, and compliance, facilitating effective cooperation and change
management while preserving data integrity.

The project intends to provide a water bottle mould design that not only satisfies
structural requirements but also embodies efficiency, creativity, and teamwork
by integrating these features and advantages. The project aims to set new
standards in mould design by utilising 3DEXPERIENCE, promoting robust and
sustainable solutions for the future.

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1.5.2 Existing Design

Fig 1.7 Existing design of mold

Functionality, manufacturability, and cost-effectiveness are given top priority in

the standard method that is now used in water bottle mould design. The main
characteristics of the current design paradigm are as follows:
Design of the Cavity and Core: The delicate elements of the water bottle shape,
such as threads, ribs, and embossments, can be precisely modelled by utilising
CAD software to construct the core and cavity. For these components to survive
the high temperatures and pressures of the blow moulding process, premium
tool steels like P20, H13, or stainless steel are frequently used in their creation.
The core and cavity designs additionally consider the plastic material's
shrinkage and warpage during cooling, guaranteeing that the finished moulded
parts adhere to quality standards and dimensional tolerances. .

Cooling System: To remove heat from the mould cavity during the blow
moulding process, a complex network of cooling channels is positioned
strategically as part of the mould design's cooling system. These channels are

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intended to prevent localised hot spots, which can cause uneven cooling and
warpage in the moulded pieces, and to guarantee uniform cooling of the mould.
By considering variables including flow rates, pressure drops, and the cooling
medium's thermal conductivity, sophisticated simulation techniques can be
utilised to optimise the cooling system's design. .

Gate Style: Gates are crucial components in the blow moulding process because
they allow molten plastic to enter the mould cavity and regulate the flow of the
material. These channels are intended to prevent localised hot spots, which can
cause uneven cooling and warpage in the moulded pieces, and to guarantee
uniform cooling of the mould. By considering variables including flow rates,
pressure drops, and the cooling medium's thermal conductivity, sophisticated
simulation techniques can be utilised to optimise the cooling system's design.
Gate Style: Gates are crucial components in the blow moulding process because
they allow molten plastic to enter the mould cavity and regulate the flow of the
material. The viscosity of the material, moulding cycle time, blow pressure, and
component geometry are all taken into account in the gate system design.

Ejector System: After the moulded pieces have cooled and set, the ejector
system in the mould design is used to drive them out of the mould cavity. It
consists of ejector pins, sleeves, or plates. The ejector system's design makes
sure that enough force is used to expel the pieces without endangering the
mould or the parts.To guarantee uniform part ejection, ejector pins are usually
placed strategically around the mould cavity's perimeter in array form.

Venting: During the blow moulding process, venting is necessary to release

trapped gases and air from the mould cavity. This helps to avoid flaws like air
pockets, burn marks, and incomplete filling. Venting is accomplished by
deliberately placing vents, micro-perforations, or venting grooves in the mould
design to allow gases and air to escape without sacrificing part quality.
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To ensure efficient venting during the moulding process, the venting system is
designed with consideration for variables including component geometry,
material viscosity, blow pressure, and mould temperature.
Surface Qualitativeness: To get the correct texture, look, and quality in the
finished moulded pieces, the mould cavity's surface finish is essential. To obtain
the desired surface quality, a variety of surface finishing processes can be used,
such as chemical etching, texturing, or polishing. Surface finishing process
selection is influenced by a number of variables, including part shape, material
type, aesthetic needs, and functional concerns.

In general, a wide range of elements are taken into account while designing
water bottle moulds, including core and cavity design, cooling system
optimisation, gate design, ejector system configuration, venting, and surface
finishing. Every component is painstakingly designed to guarantee the
economical and superior production of water bottles that satisfy exacting
performance and quality requirements.

1.5.3 Material selection

In choosing materials for water bottle moulds, it's important to take things like
corrosion resistance, thermal conductivity, and durability into account. Because
of their exceptional heat conductivity, aluminium moulds allow for quick
cooling, which cuts down on cycle times and boosts output. They are also
lightweight and resistant to corrosion, which makes them perfect for large-scale
manufacturing. Stainless steel moulds are ideal for food-grade applications
because of their exceptional strength and resistance to corrosion, which
guarantees dimensional stability throughout long production runs. PET plastic
moulds are lightweight, simple to make, and appropriate for small to medium
production volumes. They are also reasonably priced and compatible with PET
bottle material. P20 steel moulds are adaptable for moderate production
quantities since they have good wear resistance and machinability. High
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hardness and heat conductivity are characteristics of tool steels like H13, which
makes them appropriate for high-volume production while preserving exact
mould dimensions for reliable bottle quality. For moulds that need to be
precisely regulated in temperature, copper alloys with outstanding thermal
conductivity, including beryllium copper, are perfect because they can tolerate
elevated working temperatures. The process of choosing water bottle moulds is
influenced by various aspects such as production volume, budget, and
application requirements, all of which offer advantages.

1.5.4 Modified Design

Fig 1.8 Modified design of mold

In blow moulds, conformal cooling channels deviate from conventional cooling

channel designs. Conformal cooling channels are arranged in a way that closely
conforms to the mould cavity's curves, as opposed to following a linear or
straight design. This novel method of mould cooling has many benefits over
traditional cooling systems and might completely change the blow moulding
procedure used to make water bottles.

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Conformal Cooling Channel Benefits: Enhanced Cooling Efficiency: By
increasing contact between the cooling liquid and the mould surface, conformal
cooling channels maximise heat transfer. The moulded pieces cool more
effectively as a result of this increased heat conductivity. Conformal cooling
channels serve to minimise temperature differentials and lower the possibility of
localised hot spots by uniformly cooling the entire mould cavity's surface area.
Shorter cycle times and higher manufacturing throughput are the results of this.

Decreased Warpage and Distortion: Common moulding flaws like warpage,

shrinkage, and distortion are lessened by uniform cooling made possible by
conformal cooling channels. Unequal cooling and consequent part flaws are
greatly decreased when the mould cavity is kept at a constant temperature.

The dimensional stability and surface polish of water bottles made using moulds
fitted with conformal cooling channels are enhanced, leading to superior final
products that satisfy exacting quality requirements.

Increased Energy Efficiency: The entire energy consumption related to mould

cooling is decreased by the effective cooling offered by conformal cooling
channels. Reducing the length of time that each moulding cycle's cooling phase
lasts minimises energy consumption and related expenses.
This improved energy efficiency lowers the carbon footprint of the blow
moulding process, which benefits environmental sustainability in addition to
potentially saving manufacturers money. .

Design freedom and Enablement of Complex Geometry: Conformal cooling

channels provide unmatched design freedom, facilitating the easy navigation of
complex mould contours and geometries by mould designers. Due to this
creative flexibility, water bottles with intricate features and forms that would

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have been difficult or impossible to produce in the past can now be produced.

Manufacturers can take use of this design versatility to set their products apart
from the competition and satisfy changing consumer demands for creative and
visually appealing water bottle designs. Design Optimisation and Simulation:
To achieve the best possible results using conformal cooling channels,
meticulous design optimisation and simulation are needed. Conformal cooling
channel performance can be modelled and analysed under a range of operating
situations using sophisticated CAD software and simulation tools. Mould
designers can obtain the best possible cooling efficiency and part quality by
fine-tuning the layout and location of cooling channels through design iterations
and simulations. Manufacturability and Production Integration: In order to
accomplish the required complicated geometry, conformal cooling channels
may require the use of specialised manufacturing techniques, such as high-
speed milling or additive manufacturing. It takes cooperation between
manufacturing engineers, toolmakers, and mould designers to guarantee that the
design can be successfully converted into a working mould that satisfies
production needs. In order to minimise interruption and maximise efficiency,
conformal cooling channels should also be taken into consideration for
integration with current production processes and equipment. .

Procedures for Upkeep and Cleaning: The effectiveness of conformal cooling

channels may be hampered by blockages or contamination, hence proper
maintenance and cleaning practices should be implemented. To make
maintenance easier and extend the life of the mould, accessibility to the cooling
channels should be taken into account at the design stage. A major development
in blow moulding technology, the incorporation of conformal cooling channels
into water bottle mould design offers a number of advantages, such as increased
cooling efficiency, better part quality, energy efficiency, and design flexibility.
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Manufacturers may streamline their operations, cut expenses, and satisfy the
market's rising demand for premium, environmentally friendly water bottles by
adopting this creative strategy. To ensure long-term performance and
dependability, however, effective implementation necessitates careful
consideration of design optimisation, manufacturability, and production
integration in addition to regular maintenance and cleaning regimens.
Conformal cooling channels are expected to be essential in propelling
innovation and competitiveness in the water bottle production business as the
blow moulding sector develops further.

1.5.5. MASS PRODUCTION:

In mass production, this design helps with increasing the efficiency as the mold
temperature can be controlled beyond crossing its limit with the colling
channels which makes this design suitable for Mass production in industries.
Passage of cold air in the channels, when the temperature of the mold increased
heavily while manufacturing of enormous amount of product helps to control
the temperature and the production rate can be increased. In mass production,
the time of passage of cold air in channels should be controlled or it can be
automated by making the air passage in the channels when a specific
temperature is reached.

1.6 FUTURE SCOPE OF THE PROJECT:

The future scope of the project "Water Bottle Mold Design with Conformal
Cooling Channels" - Conformal cooling channels are a major blow moulding
technology innovation that can be applied to the design of water bottle moulds.
In terms of cooling efficiency, part quality, energy efficiency, and design
flexibility, this novel technique offers unmatched advantages. The scope of this
project has enormous potential for future innovation and advancement as the

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blow moulding industry develops. .

Advanced Material Selection and Integration: Research and development

activities in the future can concentrate on investigating novel materials and
production methods that improve conformal cooling channels' functionality and
performance even more. Heat transfer characteristics and cooling efficiency
may be greatly enhanced by including cutting-edge materials into the mould
design, such as ceramics, metal matrix composites, or thermally conductive
polymers. Furthermore, the development of additive printing technology may
make it possible to fabricate intricate cooling channel shapes with hitherto
unheard-of accuracy and customisation.

Computational Modelling and Simulation for Optimisation: The project's future

goals include optimising conformal cooling channel performance and design by
utilising cutting-edge computational modelling and simulation approaches.
Designers can pinpoint areas for enhancement and optimisation by utilising
computational fluid dynamics (CFD) simulations to examine fluid flow patterns,
heat transfer properties, and pressure gradients inside the cooling channels.
Based on input characteristics like part shape, material properties, and operating
circumstances, cooling channel designs can be predicted and optimised with the
use of machine learning and artificial intelligence algorithms.

Including Smart Technologies: Smart technologies like sensors, actuators, and

embedded electronics may be incorporated into water bottle mould designs in
the future to allow for real-time cooling channel performance monitoring and
control.
The mould cavity's sensor networks may offer useful information on
temperature profiles, flow rates, and cooling rates. This information would
enable adaptive control strategies to maximise component quality and cooling
efficiency. As operational conditions change, smart actuators could dynamically

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modify cooling channel layouts to guarantee optimal performance all the way
through the blow moulding process.

Eco-Friendly and Sustainable Solutions: The project's future goals include

investigating environmentally responsible and sustainable approaches to
designing water bottle moulds with conformal cooling channels.
Recycled materials, bio-based polymers, and eco-friendly manufacturing
techniques could be used to lessen the environmental effect of blow moulding
and mould creation. Methods for life cycle assessment (LCA) can be used to
examine conformal cooling channel designs' environmental impact and pinpoint
areas in need of additional optimisation and sustainability.

Digitalization and Integration for Industry 4.0: Conformal cooling channels are
incorporated into the design of water bottle moulds in a way that is consistent
with Industry 4.0 and the continuous digitization of production processes.
With the use of digital twin technology, virtual representations of the cooling
system and mould may be made, enabling predictive maintenance, real-time
monitoring, and cooling performance optimisation. .

The design iteration process can be expedited and time to market accelerated by
using digital workflow solutions and cloud-based collaboration platforms to
enable smooth communication and cooperation between designers, engineers,
and manufacturers.

The "Water Bottle Mould Design with Conformal Cooling Channels" project
has a lot of potential to innovate and enhance blow moulding technology in the
future. Through the utilisation of sophisticated materials, computer simulation,
intelligent technologies, and eco-friendly approaches, designers and producers
might seize novel prospects for augmenting cooling effectiveness, elevating
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component calibre, and diminishing ecological footprint. The incorporation of
conformal cooling channels is a crucial facilitator for promoting creativity,
efficacy, and sustainability in the production of water bottles as the blow
moulding sector develops further. .

The project "Water Bottle Mould Design with Conformal Cooling Channels"
has the potential to explore multiple areas of innovation and optimisation in the
future. The investigation of new thermally conductive polymers and metal
matrix composites will be made possible by advances in material science, which
will transform the cooling channels' heat transfer characteristics. In-depth fluid
dynamics and thermal analysis will be possible thanks to computational
modelling and simulation, which will also make it possible to optimise cooling
channel shapes and flow patterns. An era of real-time cooling performance
monitoring and modification will be ushered in by the integration of smart
technologies, such as sensor networks and adaptive control systems.
Furthermore, research on environmentally friendly materials and manufacturing
techniques, backed by thorough life cycle assessments, will be a major
emphasis.

The project will be grounded in Industry 4.0 concepts, which will promote
digital twin technology for virtual replication and mould design optimisation.
Additionally, cloud-based platforms will enable smooth data interchange and
communication among stakeholders. This all-encompassing strategy for
innovation and optimisation portends a time when the production of water
bottles will reach hitherto unheard-of levels of sustainability, quality, and
efficiency.

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1.7 CONCLUSION

In summary, the incorporation of conformal cooling channels into the

design of water bottle moulds is a revolutionary development in blow moulding
technology that will have a significant impact on the lifespan, cooling
effectiveness, and production rates of the moulds. The incorporation of
conformal cooling channels radically modifies the way heat is distributed within
the blow mould. Thermal stresses are reduced by carefully positioning these
channels to closely match the mould cavity's curves, which eventually results in
less wear and tear on the mold's components. By minimising temperature
variations throughout the mould, this enhanced cooling system reduces the
possibility of thermal fatigue and increases the mold's useful life. As a
consequence, producers have lower maintenance needs, fewer mould changes,
and less downtime, which saves a lot of money and boosts output overall.

Enhanced Cooling Efficiency: Because conformal cooling channels may

precisely adhere to the contour of the mould cavity, they offer better heat
transfer qualities than standard cooling systems. During the blow moulding
process, the molten plastic cools more quickly and uniformly because to this
increased cooling efficiency. Cycle times are thereby significantly shortened,
enabling shorter production runs and higher throughput. Further boosting total
manufacturing productivity and product consistency is the precise control of
cooling offered by conformal channels, which also helps to enhance part quality
with fewer defects like warping, sink marks, or surface blemishes.

Accelerated Production Rates: A major benefit of designing water bottle moulds

with conformal cooling channels is the notable boost in production rates.
Shorter cycle times for each moulding cycle are a direct result of these channels'
ability to facilitate faster and more effective cooling. Moulds that cool more
quickly and reliably let producers to produce more in the same amount of time,

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increasing total production rates. In addition to satisfying the rising demand for
water bottles from consumers, this higher throughput increases supply chain
effectiveness and responsiveness to market changes, giving firms in the sector a
stronger competitive edge.

Cost Savings and Operational Gains: Adopting conformal cooling channels

offers manufacturers major cost savings and operational gains, on top of the
immediate benefits of longer mould lifespans, improved cooling efficiency, and
faster production rates. Profitability is increased and overall production
expenses are decreased when mould maintenance requirements and downtime
are decreased. Furthermore, producing more bottles faster maximises return on
investment and raises potential revenue. Optimised cooling also leads to
improved uniformity and quality of moulded parts, which reduces waste and
rework, lowers production costs, and improves overall operating efficiency.

Adopting conformal cooling channels is a strategic investment made by

manufacturers in the blow moulding sector in order to be innovative and
competitive. This is known as strategic positioning. Utilising state-of-the-art
technologies and optimising mould design procedures allows companies to
stand out from the competition, draw in new clients, and increase their market
share. Additionally, meeting the changing needs of environmentally conscious
consumers, producers can position themselves as leaders in sustainability and
product excellence by producing high-quality water bottles in an efficient and
economical manner. In the end, conformal cooling channel integration drives
producers towards a future of creativity, productivity, and competitiveness in
the ever-changing water bottle manufacturing industry.

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1.8 Reference

Gupta, V. K., Jain, N. K., & Vora, J. J. (2017). Optimization of Cooling

Channels in Injection Mould Using Computational Fluid Dynamics. Procedia
Engineering, 184, 191-198.

Tian, Y., Zhang, G., & Tang, Z. (2018). Review on Conformal Cooling
Channels Applied in Injection Mould. Procedia Manufacturing, 17, 272-279.

Park, S., Kwon, S., Yoo, J., & Lee, H. (2019). Optimization of conformal
cooling channel design in injection molding using numerical simulation and
genetic algorithm. The International Journal of Advanced Manufacturing
Technology, 102(5-8), 2339-2349.

Hasan, M., Patel, M. N., & Sheikh, A. A. (2020). Optimization of cooling

channel design in plastic injection mould. Materials Today: Proceedings, 37,
2448-2451.

Zhang, S., Qian, J., & Zhang, G. (2021). Research on mold temperature field
analysis and optimization of water bottle mold with conformal cooling
channels. Journal of Materials Research and Technology, 11, 1534-1545.

Huang, Q., Zhang, Y., & Wang, W. (2022). Design optimization of conformal
cooling channels in injection molds using finite element analysis and multi-
objective genetic algorithm. Journal of Manufacturing Processes, 68, 345-354.

Geng, D., Wang, X., & Liu, Y. (2022). Design and optimization of conformal
cooling channels for injection molding based on genetic algorithm. The
International Journal of Advanced Manufacturing Technology, 123(1-4), 41-53.

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