The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization

•The ECO mold with a surface-type conformal cooling channel was designed using CFD analysis.•The ECO mold was additively manufactured via LPBF in practice.•The additively manufactured ECO mold was utilized in the casting production line.•The casting time and carbon emission were reduced by 21% and 0.6 kg of CO2, respectively.•The microstructural characteristic and mechanical evaluation of the as-cast product were improved.