Abstract Design of cooling channel is one of limitation in injection moldingprocess. The molding process involves in the phases like filling, cooling and ejection. Cooling phase is one of the critical phase to get quality and cycle time of part. Generally straight line drilled hole process is used in most of the industries for the mould, where uniform cooling is not achieved. Non uniform cooling or cycle time-consuming would results in design defects of cooling channel. To over conventional cooling channels, a concept of conformal cooling channel is introduced in which the uniform cooling of the mould takes place. In this paper various cooling channel designs were made to optimization of cooling effect and to minimize the cooling defects in injection molding process. Finite element analysis is used to analyze thermal stresses in the mould surface geometry generated around the mould. Taguchi method is used to obtain the optimum design of cooling channel from various designs