Researchers Test 3D Printed Milling Cutter With Conformal Cooling Channels

Researchers have published a new study testing a milling cutter with conformal cooling channels produced via selective laser melting (SLM) technology. The design aims to enable cooler, longer-running cuts for demanding material applications.

The study, published in Scientific Reports by authors Kolomy, Slany, Sedlak and colleagues, examines how additive manufacturing can create complex cooling channel geometries that would be impossible to machine conventionally.

Conformal cooling channels follow the contour of the tool rather than the straight drill paths possible with traditional manufacturing. This allows heat to be extracted more efficiently from the cutting edges, potentially extending tool life and enabling higher cutting speeds.

SLM (also known as laser powder bed fusion) builds the tool layer-by-layer from metal powder, allowing designers to embed cooling channels directly into the tool geometry without the constraints of drilled straight holes.

The research adds to a growing body of work demonstrating how additive manufacturing is enabling new tool designs that improve manufacturing efficiency. Similar conformal cooling approaches have been applied to injection molds, where 30-50% faster cooling cycles have been reported.