One of the most powerful capabilities of metal additive manufacturing is the ability to create ultra-fine internal channels, geometries that were previously impossible with traditional manufacturing. This capability is revolutionizing heat exchanger design in industries that demand maximum thermal efficiency within compact envelopes.
By printing thin-walled structures and intricate lattices, we can drastically increase internal surface area for heat transfer while minimizing pressure drop. These designs enable more effective cooling, especially in tight spaces, such as aerospace engine components, battery packs, or motorsport electronics. Internal passages as small as 200 microns can be reliably built using fine powder SLM or L-PBF systems.
Unlike traditional brazed assemblies or machined blocks with drilled channels, printed heat exchangers are monolithic, eliminating failure-prone joints or seals. Plus, additive gives us freedom to integrate mounting points, fins, or flow diverters directly into the geometry, optimizing thermal paths and structural integration.
Advanced simulation and design tools (e.g., topology optimization and CFD) play a key role here. Engineers can simulate thermal gradients and pressure drop before printing, validating performance before physical testing.
Think small, print smart, because thermal performance lives in the details.