Additively Manufactured Heat Exchangers: Why Engineers say ‘WOW’

If a picture tells a thousand words, then holding a Conflux heat exchanger in your hand tells the store of years of testing, validation and technical presentations. When our customers or additive manufacturing peers hold one of our latest additively manufactured heat exchangers, the typical reaction is a simple “wow”. Here is a summary of why these 3D printed, high performance heat exchangers create that response.

NO. 1: The Level of Detail

At first glance, the level of detail is unmistakable. The ultra-fine features, thin walls and complex internal geometries visible in each Conflux heat exchanger are the result of deep expertise in both heat exchange and metal additive manufacturing.

Our custom build parameters enable us to achieve these sought-after thin structures while retaining strength and meeting demanding thermal performance targets. This combination of intricate internal geometry and robust, gas-tight walls is very difficult – and often impossible to achieve using conventional manufacturing.

Our Water Charge Air Cooler (WCAC) is a prime example of how our 3D printed heat exchangers can out-perform leading comparable WCACs in a compact, lightweight package. You can learn more about the technology outperformed a leading micro-tube heat exchanger in this Conflux Water Charge Air Cooler vs Microtube Heat Exchanger case study.

NO. 2: Powder Removal, Done Properly

Engineers familiar with additive manufacturing know that producing impressive internal geometries is only half the challenge. Effective powder removal from fine, enclosed features is a critical hurdle for additively manufactured heat exchangers. The finer the details and the higher the surface area density, the more sever this challenge becomes.

We have developed proprietary powder removal techniques and quality control methods that keep us in pole position when it comes to delivering clean, powder-free 3D printed heat exchangers at production scale. This directly supports performance, reliability and repeatability.

Learn more about what makes our process unique in our article Post-Processing for Performance: Conflux’s Approach to Quality in AM and how AS9100D Certification: Elevating Standards in Heat Exchanger Manufacturing are important aspects of our testing and validation.

NO. 3: Additively Manufactured Heat Exchangers are Hard

Heat exchangers are well recognised as an ideal application for additive manufacturing – they can benefit from improved thermal performance, reduced weight and superior control over packaging constraints. However, extracting all the potential value that additive manufacturing can bring to heat exchangers is a formidable challenge.

Designing and producing additively manufactured heat exchangers demands a deep understanding of thermal management, fluid dynamics, lattice and fin design, and the realities of metal AM processes. As thermal pioneers, we have invested heavily in this intersection of disciplines and are proud to be global leaders in AM heat exchanger design and production.

No. 4: The Moment of Discovery

There is always a moment of discovery when someone holds one of our heat exchangers for the first time. It is a genuine “wow” experience as they realise what they are rolling around in their hands: an ultra-compact, highly optimised, additively manufactured heat exchanger that simply could not exist using conventional manufacturing methods.

For us, that moment is important. It carries an element of vindication as the results of our years of R&D, testing, and manufacturing innovation are recognised by our peers and customers. For them, it often marks the beginning of a new way of thinking about thermal management and system design.

Curious about what an additively manufactured Conflux heat exchanger could do in your application? Find out more by speaking with one of our experts or catch us at an upcoming event.