The rapid development of high-power electronic devices such as electric cars, computers, aircraft, and industrial equipments have posed numerous challenges and high demands for cooling efficiency.
In this article, you will have a chance to explore a new cooling technology for electric cars, produced by advanced metal 3D printing. With a lattice design fearturing an S-shaped thing, the cold plate increases its surface area by 300%, reducing the component's weight and enhancing cooling performance
1. What is a heat exchanger?
A heat exchanger is an essential component in many systems and engines, from air conditioners to car engines and rockets. Its primary function is to transfer heat between a heat source and a fluid, thereby cooling or heating devices. Heat exchangers ensure high performance and extended lifespan for electronic devices. Depending on their application, heat exchangers can be categorized into various types such as liquid-to-gas, liquid-to-liquid, and liquid-to-solid heat exchangers, also known as cold plates, ...
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2. Case-study: Metal 3D printed Cold plate for electric race cars – A future of electric vehicle industry
A team of students from Dynamis PRC at the University of Milan found that electric Formula SAE race cars, whose inverters convert DC power from the battery to AC power for motor control, must operate within a specific temperature range. To maintain this range, electric race cars must incorporate liquid-cooled heat exchangers to dissipate heat from the inverter.
(Electric race car) (source: nTop)
The team collaborated with M4P and Puntozero to develop a metal 3D printed cold plate for electric race cars. Beyond cooling capabilities, the lattice structure reduces the size and weight of the cold plate, while increasing surface area. This design optimizes coolant flow, leading to energy savings and enhanced cooling performance
2.1. Structure and design of 3D printed metal Cold plate
Structure of cold plate
One of the key differentiators of 3D printed cold plate compared to traditional ones is their lattice structure. Essentially, a lattice structure is a network of interconnected beams or plates, forming a porous solid. This structure offers the highest structural efficiency per unit weight. Therefore, lattice structures are widely used in aerospace and automotive engineering
(The metal 3D printed cold plate for electric race car)
To reduce the cold plate's weight, they used a diamond TPMS lattice structure for the outer lattice. For the inner lattice, with the aim of directing coolant flow, Puntozero decided to use a serpentine S-shaped channel with a shark fin-like internal structure. The outer lattice gradually thickens near the contact surface to enhance heat transfer
(Internal structure of 3D printed cold plate)
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Design and simulation
Engineers optimized the design process by using nTopology software, it allows designers to easily fill a space with a lattice network, which can be regular or distorted and stretched.
When designing the 3D printed cold plate, Puntozero used 2 complex lattice structures on the interior and exterior to reduce the component's weight and manufacturing cost while maintaining necessary stiffness. The lattice structure creates a large contact area between the coolant and the heat exchanger walls, significantly reducing the weight of the component, resulting in a more compact and efficient cooler
(nTopology Software Interface)
nTopology offers a suite of automated tools for efficiently generating complex lattice structures. Engineers can rapidly refine designs by adjusting parameters of variables created from previous designs, rather than repeating the entire design process. In this way, they can adjust input parameters and see results on-screen within milliseconds.
(CT Scanning by nTopology software)
Conducting computational simulations to analyze stress, deformation, and fluid flow within the lattice structure. This allows for the optimization of design parameters to eliminate dead zones (areas with near-zero flow velocity) and significantly improve pressure drop reduction.
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2.2. Manufacturing technology and materials for 3D printed Cold plate
Manufacturing Technology
- Due to its complex lattice structure, the heat sink is produced using advanced metal 3D printing technology - Laser Powder Bed Fusion. This process involves repeatedly melting or fusing powdered materials using a laser beam.
Material
- The product is manufactured using M4P's Pure Al aluminum powder, which is very similar to pure aluminum but with some adjustments to suit 3D printing technology, resulting in high-strength and smooth surface products
2.3. Advantages and Challenges of 3D printed metal Cold plate
Advantages
Increased surface area: The lattice structure increases the surface area for heat transfer between the coolant and the material by up to 300% compared to conventional designs.
High cooling performance: The increased surface area between the fluid and the component wall optimizes cooling and heat transfer processes.
Reduced weight: The lattice structure reduces the cold plate's weight by 25%, making it ideal for race cars and other applications requiring lightweight components.
Design freedom: Metal 3D printing technology enables the creation of complex shapes, improving cooling efficiency.
Enhanced powder removal: Areas further from the contact surface are designed to be thinner, facilitating powder removal during post-processing.
Challenges:
Production cost: Production costs remain higher compared to traditional methods.
Surface finish: Post-processing is often required to meet technical and aesthetic requirements.
Production scale: The component is designed for a specific vehicle and is not suitable for mass production.
2.4. Applications and future development
In addition to electric race cars, lightweight 3D printed metal cold plate can be applied in various fields such as:
Aerospace: Cold plates with optimized structures, lightweight, and compact designs play a crucial role in ensuring the stable and efficient operation of electronic devices in the harsh environments of aerospace applications, including airplanes, helicopters, spacecraft, and satellites.
(Heat exchanger for helicopter)
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Electric car: The thermal management of electric vehicle batteries is a growing concern. During operation, especially during fast charging or high-intensity usage, heat is generated. Excessive battery temperature can reduce battery life, impair performance, and in severe cases, cause fires, posing risks to users and vehicles.
Consumer electronics: Consumer electronics such as smartphones, computers, laptops, tablets, and refrigerators require efficient cooling systems, particularly for compact, aesthetically pleasing, and high-performance components.
Vinnotek is a distributor of nTopology software and provides design and simulation services. Additionally, we offer a range of SLM metal 3D printers tailored to the needs of businesses in various industries.
Contact us to elevate your manufacturing process!
Source: 3D Printed Cold Plate for an Electric Race Car: The Cool Parts Show
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