Aerospace Thermal Solutions

Improving heat transfer for aerospace applications including rocket engines, eVTOLs, satellites, and more

High performance

Develop heat exchangers into contoured packaging, lower weight and adopt industry leading performance

Reduced Costs

Reduce development time and costs by applying focused heat exchange design, simulation and additive manufacturing expertise

Path to production

Leverage our vertically integrated organization to support verification, production readiness and serial production

Optimize Aerospace Development with Additive Manufacturing Expertise

Expertise and experience in heat transfer to accelerate your development programs

  • Applications - lower your R&D expenditure by applying a Conflux CoreTM geometry to your heat exchange challenge.
  • Analytics - leverage our synchrotron CT scanning and advanced Conflux Quantify analytics for your parts and materials analysis.
  • Connecting the dots - travel the complex path of testing and certifying parts, materials and processes for flight with an experienced team, familiar with Aerospace primes.
  • Our commitment to quality is affirmed by AS 9100D certification, ensuring excellence in aerospace solutions.

Additive manufacturing for aerospace

Aerospace companies have been quick to identify the advantages of Additive Manufacturing and are adopting it through various aerospace applications. Initially, it allowed for the shortening of development time with form, fit and functional tests. As the technology has matured, aerospace companies are now able to validate additive manufacturing and are building up a database of both materials and process. The notion of certifying airworthy additive manufactured components is now a compelling option.

Benefits of Additive Manufacturing in Aerospace:

Part Consolidation

Conflux develops solutions that reduce the number of parts in sub-assemblies for aerospace companies. By removing part interfaces and combining multiple parts into a monolithic additive manufactured structure, we remove failure points that can result from brazing, welding, bonding or bolting parts together. This can lead to an increase in the mean time between failures alongside an increase in the performance of parts.

Shorter development process and time to market

Conflux realises faster development cycles through application “sprints” that bring together design engineers, thermo-fluid engineers and AM experts into cross-disciplinary teams. For our customers, this means initial results sooner informing development directions and ultimately faster speed to market in comparison to traditional manufacturing processes. Conflux builds and test parts as part of these “sprints”.

Higher Performance

With traditional manufacturing processes, developing topologically optimised designs is extremely challenging due to the complex shapes and the inherent limitations of the conventional manufacturing processes. In contrast, Conflux’s mastery of AM and heat transfer allows for greater flexibility in both design and manufacturing, leading to significant performance advantages.

Lighter Weight

Being able to design and manufacture lightweight components is a key driver for the adoption of AM in the aerospace industry. Here at Conflux, we have designed and produced lighter weight, higher performing parts to help our customers achieve their weight savings targets without sacrificing performance. Our development of high performance heat exchangers shows that the combination of AM expertise, simulation and design experience, is necessary to exceed customer requirements for weight reduction.

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Heat Exchangers for Aerospace Applications

  • Pre-Cooler
  • Oil to Air Heat Exchanger
  • Fuel Oil Heat Exchanger
  • Hydraulic Oil Heat Exchanger
  • Environmental Control System Heat Exchanger
  • Bleed Air Cooler
  • Coolant to Air Heat Exchanger
  • Cold Plates
  • LRU Cooling
  • Electronics Cooling
  • How additive manufactured cold plates improve thermal performance for Advanced Air Mobility

    At the heart of these electric Vertical Take Off and Landing (eVTOL) vehicles lies the electric powertrain. This consists of a lithium-ion battery along with high performance motors and inverters which generate the necessary lift and propulsion. There are a variety of different powertrain concepts currently being developed, however they all share the same thermal management challenges that come with high power and high voltage electronics.

    Read the article