Solid State Additive Manufacturing for Multi-Metal Heat Exchangers

Over the last few years, 3D printing has promised designers freedom of geometry. Solid state (no melting) 3D printing processes are now allowing freedom of material. New processes leverage ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. This low temperature attribute of the process enables printing multiple metals in one part, creating complex internal channels, and embedding electronics into solid metal. These attributes have been leveraged to create millions of electrification components in the automotive space – both electrical busbars and complex heat exchangers. This presentation will provide an overview of the welding technique and provide several specific case studies:

• Multi metal radiators for satellites that enabled 30% lower weight and 30% improved thermal performance by eliminating thermal interfaces
• Cold plates that integrate aluminum, copper, and embedded electronics in one single print job
• Multi-metal busbars and flexible connections for thermal applications