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.

In injection molding, advanced numerical modeling tools, such as Moldex3D, can significantly improve product development by optimizing part functionality, structural integrity, and material efficiency. However, the complex and nonlinear interdependencies between the several decision variables and objectives, considering the various operational phases, constitute a challenge to the inherent complexity of injection molding processes. This complexity often exceeds the capacity of conventional optimization methods, necessitating more sophisticated analytical approaches. Consequently, this research aims to evaluate the potential of integrating intelligent algorithms, specifically the selection of objectives using Principal Component Analysis and Mutual Information/Clustering, metamodels using Artificial Neural Networks, and optimization using Multi-Objective Evolutionary Algorithms, to manage and solve complex, real-world injection molding problems effectively. Using surrogate modeling to reduce computational costs, the study systematically investigates multiple methodological approaches, algorithmic configurations, and parameter-tuning strategies to enhance the robustness and reliability of predictive and optimization outcomes. The research results highlight the significant potential of data-mining methodologies, demonstrating their ability to capture and model complex relationships among variables accurately and to optimize conflicting objectives efficiently. In due course, the enhanced capabilities provided by these integrated data-mining techniques result in substantial improvements in mold design, process efficiency, product quality, and overall economic viability within the injection molding industry.

In injection molding, advanced numerical modeling tools, such as Moldex3D, can significantly improve product development by optimizing part functionality, structural integrity, and material efficiency. However, the complex and nonlinear interdependencies between the several decision variables and objectives, considering the various operational phases, constitute a challenge to the inherent complexity of injection molding processes. This complexity often exceeds the capacity of conventional optimization methods, necessitating more sophisticated analytical approaches. Consequently, this research aims to evaluate the potential of integrating intelligent algorithms, specifically the selection of objectives using Principal Component Analysis and Mutual Information/Clustering, metamodels using Artificial Neural Networks, and optimization using Multi-Objective Evolutionary Algorithms, to manage and solve complex, real-world injection molding problems effectively. Using surrogate modeling to reduce computational costs, the study systematically investigates multiple methodological approaches, algorithmic configurations, and parameter-tuning strategies to enhance the robustness and reliability of predictive and optimization outcomes. The research results highlight the significant potential of data-mining methodologies, demonstrating their ability to capture and model complex relationships among variables accurately and to optimize conflicting objectives efficiently. In due course, the enhanced capabilities provided by these integrated data-mining techniques result in substantial improvements in mold design, process efficiency, product quality, and overall economic viability within the injection molding industry.