Evaporative Cooler Mold: Engineered for Thermal and Hydraulic Synergy

Evaporative cooler molds represent a specialized category of industrial tooling designed to manufacture the critical components of evaporative cooling systems. These molds are engineered to produce parts that operate at the unique intersection of airflow management and water distribution, demanding precision in both structural integrity and functional surface design.

Unlike standard cooling system molds, our designs focus on the dual-phase performance of components like cooling pads, water distribution trays, and multi-channel housing. The mold architecture incorporates hybrid gating systems that prevent weld lines in critical flow-path areas, ensuring unimpeded water sheeting and air penetration. For the porous cooling media structures, we employ specialized breathable steel inserts and variable-pressure venting systems to achieve consistent cell structure formation without surface defects.

Corrosion-resistant tool steels with specialized coatings are essential, as these molds process mineral-filled polymers and hydrophilic materials. The cooling systems feature independent circuit clusters that provide differentiated thermal management—rapid cooling for thick structural ribs, and moderated cooling for thin water-contact films. This prevents stress concentration in parts subjected to constant wet-dry cycling.

Dimensional stability is achieved through moisture-compensated shrinkage algorithms in the design phase, accounting for material expansion during water saturation. Critical components like louvered air inlets are formed using sequential angled core pulls that create precise aerodynamic profiles while maintaining draft-free surfaces.

These molds enable the production of components that maximize the evaporative cooling effect—increasing cooling efficiency by 25-30% compared to conventional designs while reducing water consumption.