Design & Engineering

Leverage the benefits of Additive Manufacturing

Design for a new paradigm in manufacturing

Accelerate your competitive advantage by leveraging our unique combination of expertise in AM design and heat transfer engineering. Using first principle calculations, our expert team take a clean sheet approach to the problem space and truly exceed the limits of historical heat exchange design rules.

Specialising in heat exchangers designed from first principles, our competitive mindset means we are constantly pushing the technological boundaries of AM in our search for superior performance. We have the perfect blend of skills, experience and knowledge for rapid ideation and concept creation. Harnessing agile methodologies, our hand-picked team, led by senior design engineers consistently and successfully deliver solutions from ideation through to physical parts.

Designing for Additive Manufacturing

We reach innovative solutions by focusing on specialist application development.

DfAM (Design for Additive Manufacturing) forms a critical part of our development cycle. Our team’s combined experience provides our customers with high value adding capabilities.

Our unique capabilities:
  • 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
Speak to one of our AM Specialist

ABOVE: This video showcases the complex designs that Conflux develops

Experts in Heat Exchanger Design

With more than 20 years’ experience in designing thermal management systems across a range of high performance industries, we work with our customers to develop the best possible solution with minimal compromises. Our team possess high systems-level knowledge of thermal management and cooling systems across multiple platforms. This enables us to look at the problem space holistically, proposing both swap-in-swap-out solutions and identifying opportunities for part consolidation.

Simulation is critical to enhance designs

Multiphysics simulation and analysis are critical to our engineering workflow. Our calculations engineers perform CFD (Computational Fluid Dynamics) simulation to initially predict performance and inform our designs. We also engage in early stage FEA (Finite Element Analysis) to investigate structural implications and evaluate whether our designs are durable enough to withstand the end use or test environment.

We perform CFD not only to predict performance characteristics such as heat rejection and pressure drop, but to gain detailed insights into the specific regions of geometry that provide the highest heat transfer with the lowest impact on flow. Correlation of the simulated performance with physical test results is essential for validating our simulation models and we always recommend performing this step for our customers.

Once correlation has been performed, our engineers then have a more accurate model that can be used to rapidly refine and optimise designs through additional iterations.

ABOVE: The image above show (left) a Micro electronic heat simulation and a video of a R&D build in progress (right).

“Heat exchangers are extremely well suited to AM. However, the experience at Conflux proves that a deep understanding and combination of Design for AM (DfAM), fundamental principles of heat transfer/fluid mechanics, thermo-fluid simulation and AM process know how are required to achieve competitive results. An attractive, well designed AM part is not enough on its own”.

Kevin Hazlehurst, AM Consultant

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