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Working with Conflux Technology

At Conflux, we provide our customers with an end-to-end manufacturing service through vertical integration. Our team of AM experts can design, simulate and manufacture heat exchangers configured to your specific boundary conditions.

Design for Additive Manufacturing (DfAM)

Our processes encompass ideation, design engineering, simulation, AM prototyping, production, post processing and testing.

We combine DfAM (Design for AM) expertise with the fundamental principles of heat transfer, underpinned by thermo-fluid simulation and a mastery of AM processes.

By applying in-depth knowledge of AM technology best practice, its constraints and all of its supporting processes, we’re able to realise the full potential of AM heat exchangers and achieve step changes in thermal.

We design highly complex geometries from first principles through our specialist DfAM methodology.

We perform Computational Fluid Dynamics (CFD) simulation and Finite Element Analysis (FEA) to predict the performance of our parts and ensure we maximise design potential.

Characteristics such as heat rejection and pressure drop are improved as we optimise heat flux and fluid flow.


Heat Transfer Simulation

We perform Computational Fluid Dynamics (CFD) simulation and Finite Element Analysis (FEA) to predict the performance of our parts and ensure we maximise design potential.

Characteristics such as heat rejection and pressure drop are improved as we optimise heat flux and fluid flow.

Our unique thermal expertise:

  • Rapid development cycles
  • Innovative ideation and concept creation
  • Clean sheet approach, developing designs from first principle calculations
  • Agile and robust design methodology
  • Detailed CAD modelling – from concept through to production ready drawings
  • Newest Product

    Conflux’s cold plate heat sink

    Conflux’s cold plate heat sink is ultra-lightweight and can conform to any cooling system.

    Laser Powder Bed Fusion for metal Additive Manufacturing

    Laser Powder Bed Fusion (LPBF) is what we use as our metal AM technology. LPBF uses a fibre laser to selectively melt fine metal powder in order to form the desired three-dimensional object. The laser beam passes through a system of lenses and is directed and positioned by two highly precise mirrors.

    After a layer of powder is selectively melted, the build platform/part is lowered. Another layer of powder is spread across the part using a recoating mechanism and the laser melting process is repeated. This layer by layer process repeats itself until the final height of the part has been realised.

    We have chosen laser powder bed fusion technology for its ability to create the highly dense, thin walled, complex features that are critical for the best performance in heat transfer.


    Vertically Integrated Additive Manufacturing Facility


    At Conflux, we provide our customers with an end-to-end manufacturing service through vertical integration and our validated supply chain.

    Our team of experts take customers through from design concept, performance simulation, testing, and final manufacture. At our site outside Melbourne, Australia, we have multiple LPBF systems installed.

    We are a platform agnostic company and will be adding more systems to our facility to enhance our manufacturing capabilities.

    Metal Materials for Heat Exchangers

    To meet the needs of our wide requirements of customers, we work with a range of commercially available additive manufacturing materials in order to deliver high-end heat exchangers, including:

    • Aluminium alloys
    • Stainless steels
    • Monel K 500

    Our R&D department is continually researching new and novel materials for various thermal applications.

    Testing & Quality

    Build, validate and test
    We optimise performance characteristics within a rapid development timeline. Starting with strategic and partial builds that are processed as part of an iterative development cycle, we are constantly evaluating manufacturability.

    A combination of physical, non-destructive and destructive testing methods enables us to validate our designs, establish their performance and optimise their efficiency.
    Our approach creates a risk-reduced pathway to the successful build of full-scale, functional AM components.

    Refine and optimise
    We use a variety of in-house and independent laboratories as well as in-field testing programs to confirm the quality, integrity and performance of our functional prototypes. We have unique access to ANSTO’s Australian Synchrotron, allowing us to verify the outcomes of our custom parameter developments and inspect for critical defects.

    By correlating initial test data with our simulation results, we trigger the optimisation phase of our workflow using our proprietary software Conflux Quantify. We reanalyse, modify and refine designs to identify and extract their maximum performance potential and provide customers with a fully optimised, one-of-a-kind solution.

    We are AS9100D certified.

    Image - Testing
    Image - ANSTO

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