Additively manufactured heat exchangers

Additive manufacturing offers new possibilities in the production of heat exchangers, especially where conventional production processes reach their geometric or production technology limits. The layered structure allows complex cooling channels, organic structures and compact designs to be created, which enable optimized heat transfer.

What are heat exchangers?

Heat exchangers are indispensable components when it comes to transferring thermal energy between two media.

Whether in industry, air conditioning technology or the automotive sector - they ensure the efficient use of energy, regulate processes and enable the targeted cooling or heating of systems.

Conventional production - tried and tested, but limited

Traditionally, heat exchangers are made of metal - using processes such as milling, welding, soldering or bending. These methods offer solid results, but are often time-consuming and costly. Conventional manufacturing methods quickly reach their limits, especially when it comes to particularly complex internal structures that are crucial for optimum heat transfer.

Modern production technologies such as 3D printing open up new possibilities for producing heat exchangers with innovative, highly optimized geometries and further increasing efficiency.

Suitable materials for 3D-printed heat exchangers

The selection of a suitable metal depends heavily on the requirements for thermal conductivity, weight, machinability and corrosion behavior. Copper and aluminum are both suitable for additive manufacturing, but differ significantly in their physical properties.

Copper

Copper has a very high thermal conductivity and is therefore ideal for applications where maximum heat transfer is paramount.

Properties:

• Thermal conductivity: approx. 300-380W/mK
• Density: ~8.9g/cm³
• Electrical conductivity: very high
• Corrosion resistance: good, depending on the medium
• Strength: moderate, can be mechanically post-processed

Aluminium

Aluminum alloys offer a good balance of mechanical strength, weight and thermal conductivity and can be produced very well using additive manufacturing.

Properties:

• Thermal conductivity: approx. 120-150W/mK
• Density: ~2.7g/cm³
• Electrical conductivity: medium
• Corrosion resistance: very good
• Strength: good, especially after heat treatment

Typical areas of application

E-mobility

In electric vehicles, batteries, power electronics and electric motors need to be cooled efficiently. Additive manufacturing allows the production of application-specific heatsinks with integrated flow channels and optimized heat transfer with minimal installation space.

Industry and machine building

Reliable cooling solutions are crucial in industrial production, especially for high-performance machines, laser systems and converters. 3D-printed heat exchangers can be precisely adapted to process requirements and offer high thermal efficiency in a compact design.

Medical technology

Small, powerful cooling units are required for imaging procedures, laser devices or portable diagnostic systems. Additive manufacturing also allows small quantities to be produced economically, often with function-integrated housings.

Power electronics

Power supplies, frequency converters and data centers require heat exchangers that are precisely matched to the electrical components. Additive manufacturing enables direct adaptation to the respective design and heat source.

What are the advantages of 3D-printed heat exchangers?