How Conflux develops 3D printed cold plate designs for eVTOL aircraft

The emergence of electric vertical takeoff and landing (eVTOL) aircraft represents a significant leap forward in sustainable aviation. A critical aspect of this innovation is ensuring efficient thermal management while reducing the overall weight of components. Cold plates play a pivotal role in managing battery temperatures and maintaining operational efficiency. Recently, specialist Australian company Conflux has collaborated with an aerospace leader to develop a cutting-edge cold plate through additive manufacturing (AM), achieving significant improvements in both thermal performance and weight reduction.

Balancing weight and thermal performance via DfAM

As eVTOL technology advances, the need for lightweight components becomes increasingly essential to maximize energy efficiency, operational range, and payload capacity. Simultaneously, effective thermal management remains a cornerstone of battery reliability and safety. The challenge lies in designing a solution that achieves these two goals without compromising one for the other. This demand for balance drives innovation in thermal management systems, positioning cold plates as a key enabler of advanced air mobility.

To address these challenges, Conflux adopted a modular approach guided by Design for Serial Additive Manufacturing (DfSAM) principles. This strategy allowed for a cold plate design capable of cooling multiple battery packs through a single inlet and outlet, delivering unmatched scalability and flexibility. The design incorporated innovations to reduce weight and enhance thermal efficiency. Wall thickness adjustments, refined internal geometries, and precise alignment with pressure drop requirements were among the core design features. These advancements went beyond the capabilities of traditional manufacturing, highlighting the transformative potential of AM.

Cold plate design simulation and validation

The development process relied heavily on computational simulations to ensure optimal performance. Advanced tools such as computational fluid dynamics (CFD) simulations were employed to identify and mitigate issues like thermal hotspots and uneven flow distribution. These simulations allowed the team to refine the cold plate’s design iteratively, ensuring that the final product delivered exceptional thermal management while remaining compact and lightweight. This data-driven approach was instrumental in achieving design goals within the constraints of aerospace applications.

Maintaining strict flatness tolerances was vital for the cold plate’s seamless integration with the eVTOL battery packs. Precision was non-negotiable in this context, as any deviation could compromise thermal contact and, consequently, overall performance. Conflux addressed this challenge by optimizing the additive manufacturing process and implementing advanced post-processing techniques, such as surface machining and thermal treatments. These adjustments ensured the cold plate not only met but exceeded the flatness standards required for high-performance aerospace applications.

Achieving weight reduction

The pursuit of weight reduction was a central objective in this project. By iteratively refining the cold plate design, Conflux achieved a 50% reduction in wall thickness, resulting in an overall weight reduction of 42% compared to initial estimates. This achievement underscores the value of AM in producing lightweight components while maintaining the structural integrity required for demanding applications. The lighter cold plate significantly enhanced the energy efficiency and payload capacity of the eVTOL aircraft, demonstrating the far-reaching impact of weight optimization.

The optimized cold plate design incorporated advanced fluid channels and manifolding techniques to ensure even flow distribution. These enhancements reduced temperature variation across the plate’s surface by 80%, eliminating thermal hotspots that could compromise battery safety and performance. The improved flow distribution achieved uniform cooling, a critical factor in meeting the stringent thermal requirements of eVTOL applications. This advancement highlights the importance of precision engineering in thermal management systems.

With this cold plate project, Conflux demonstrated once again demonstrated how lightweight, high-performance components can be achieved through innovative design and advanced additive manufacturing techniques. The lessons learned extend beyond this project, offering insights for future advancements in thermal management and lightweight design for aerospace and other industries.

Cold plate applications across industries

While this project focused on eVTOL aircraft, the implications of the cold plate design extend to numerous other sectors. In the automotive industry, similar designs can enhance the thermal management of electric vehicle batteries. Electronics manufacturers can use these advancements for cooling high-performance computing systems. Renewable energy technologies, such as solar and wind power systems, benefit from compact and efficient thermal solutions. Additionally, cold plates have applications in medical devices and data centers, where managing heat in limited spaces is a critical challenge. This cross-industry applicability underscores the broad potential of optimized cold plate technology.

The success of this project highlights the growing role of additive manufacturing in shaping the future of aerospace innovation. AM enables the creation of intricate geometries that are impossible with traditional manufacturing methods, allowing for significant reductions in material usage and weight. These advancements align with the industry’s push toward sustainability, providing a pathway for more efficient, cost-effective, and environmentally friendly aviation technologies.