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Aviation Thermal Applications

Address weight challenges and meet rapid development timelines with AM heat exchangers.

Advanced Air Mobility

In advanced air mobility, thermal management is crucial for optimising performance and range. It regulates temperatures in electric and hybrid aircraft systems, ensuring efficient energy use while protecting sensitive components during urban operations and varying flight conditions.

 Next Generation Propulsion

Thermal systems in next-generation propulsion technologies are designed to enhance efficiency and performance. They manage heat in innovative powertrains, including electric and hybrid designs, ensuring optimal functioning under extreme operational conditions while minimising environmental impact.

 Commercial Aviation

In commercial aviation, effective thermal management is essential for passenger comfort and aircraft efficiency. It regulates cabin temperatures, manages engine heat, and protects critical components, enhancing overall performance and safety during flights across diverse climates.

Aviation Heat Exchangers

Macro Heatsink Heat Exchange

Cold Plate Heat Exchanger

 image of an Intercooler / Charge Air Cooler Heat Exchanger

Intercooler Heat Exchanger

 Charge Air Cooler

Air-Cooled Heat Exchanger (ACHE)

Discover advanced heat exchangers tailored for aviation and aerospace, including air-cooled systems, ram air heat exchangers, fuel/oil coolers, and battery thermal management solutions. Engineered for advanced air mobility, next-gen propulsion, and commercial aviation, these technologies deliver superior thermal performance, enhanced efficiency, and reliability. Ideal for eVTOLs, hybrid-electric propulsion, and traditional aircraft systems, our heat exchangers ensure peak performance under demanding operational conditions, meeting the rigorous standards of modern aerospace innovation.

 

Conflux offers ultra-thermal efficiency in compact & lightweight forms for:

Propulsion System Cooling (Next-Gen & Conventional)

Advanced thermal management for jet, turboshaft, hydrogen, hybrid, and battery-electric propulsion systems.

 Transmission & Gearbox Cooling

Compact, high-performance cooling for improved efficiency and durability in drivetrain components.

 Environmental & Avionics Cooling

Precision cooling solutions for stable avionics performance and efficient environmental control.

 Power Electronics Cooling

High-efficiency heat exchangers to manage thermal
loads in critical power electronics systems.

Discover how Conflux designed an AM cold plate for next gen aviation battery cooling

Download the case study today

Additive Manufacturing Heat Exchanger Features

Experience unparalleled performance with Conflux heat exchangers. Our innovative approach redefines what’s possible in thermal management, offering four key advantages to elevate the performance of the most demanding aerospace systems.
High thermal efficiency

Boosts aircraft performance through superior heat dissipation.

 Aerodynamic integration

Designed to seamlessly fit within airframes for enhanced fuel efficiency.

 Durability

Built to endure high-pressure, high-altitude conditions.

 Weight reduction

Lightweight construction supports fuel economy and payload maximization.

We’re excited to work with Conflux, whose reputation for delivering at Formula 1 speed combined with AS9100D manufacturing and quality certification will be critical in enabling Vertiia to become the world’s first long-range passenger-capable hydrogen VTOL. Working together, we are pioneering a future where clean energy and cutting-edge engineering drive the aviation industry towards a greener and more sustainable future.

 Simon Coburn Hydrogen Systems Engineer, AMSL Aero

Ready to discuss your aviation thermal challenges?

At Conflux, we are redefining thermal management in the aviation industry with innovative heat exchange solutions. From improving efficiency in next-gen propulsion systems to enhancing battery cooling for VTOLs and optimizing fuel systems in commercial aircraft, our technology addresses the sector's toughest challenges. Schedule a meeting to explore how our advanced solutions can elevate your performance, reduce operational costs, and give you a competitive edge in aerospace innovation.

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FAQs

What type of 3d printed aviation heat exchangers can Conflux produce?

 What type of 3d printed aviation heat exchangers can Conflux produce?

Conflux is able to design and additive manufacture the following:
Fuel oil heat exchangers, precoolers, liquid-to-gas recuperators, cryogenic heat exchangers, oil coolers, gearbox oil-to-air heat exchangers, rotorcraft transmission coolers, hydraulic oil-to-air heat exchangers, air cycle ECS heat exchangers, vapor cycle heat exchangers, ram air heat exchangers, air-to-air recuperators, liquid cold plates, air-to-liquid heat exchangers, waste heat recovery heat exchangers, phase change heat exchangers.

Resources for aviation
April 29, 2025
Conflux Technology Marks 10-Year Milestone with New UK Hub, Driving European Expansion
 March 26, 2025
Conflux partners with AMSL Aero to develop hydrogen fuel cell cooling for long range zero emissions electric Vertical Take Off and Landing (VTOL) aircraft
 March 28, 2025
Navigating Technology Readiness Levels in Additive Manufacturing

Working With Conflux

Partner with Conflux for a streamlined approach to advanced heat exchange solutions. Our process is designed to guide you from concept to optimised, high-performance outcomes.
Contact our Team
1.
Feasibility

We begin by evaluating whether an additive manufacturing heat exchanger (AM HX) will meet your thermal performance needs. Through a rough design and preliminary simulation, we provide insights into the potential success of integrating the heat exchanger into your platform, helping you make an informed decision before committing to full-scale development.

 2.
Proof of Concepts

We create a working design backed by detailed simulations and deliver a physical part. We also offer recommendations for testing the prototype to ensure it meets your operational needs. If required, we adjust the quantity of parts to suit the needs of your project.

 3.
Optimisation & Verification

We work closely with you to refine the heat exchanger design, focusing on how it will seamlessly integrate with your platform. This iterative process includes performance optimisation and operational testing to ensure the part functions as intended in real-world conditions. The goal is to achieve final design approval through collaborative, hands-on development.

 4.
Qualification

We ensure your heat exchanger meets industry qualification standards, including those related to our additive manufacturing processes. This phase focuses on producing a functional part and verifying the manufacturing process, with all requirements typically driven by your specific industry standards, ensuring readiness for production.