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Beamler and Calyos successfully design and produced a 3D printed, pure copper pulsating heat pipe.
Beamler and Calyos successfully 3D printed a pure copper heat pipe (PHP or Pulsating Heat Pipe), proving the feasibility and effectiveness of such a project. This proof of concept marks a milestone in the production of PHP by additive manufacturing (AM).
As part of a recent research project analyzing pulsating heat pipes, Calyos chose Beamler as a partner to produce the 3D printed prototype. Beamler have since produced an article that aims to give an in depth analysis of the additive manufacturing of pure copper applied to heat pipes.
Here is an extract from the article:
"The device was 3D printed with pure copper using Laser Powder Bed Fusion (L-PBF). Pure copper has one the highest thermal conductivity of all metals, about 0.4 kW/(m.K) [2]. However, much higher thermal conductivity can be achieved with PHP up to 12 kW/(m.K) thanks to their working principles. The 3D printed pure copper heat pipe is a square prism of about 100 mm lengths for sides and 11 mm height. The images below show the blueprints and CAD model of the PHP. Internal dimensions of the channel are computed using internal software. The groove visible on the surface of the printed part are used for thermocouples. The total weight of the part is about 0.690 g. To prevent leakage of the working fluid and a loss of thermal conductivity, the part must be fully dense and the printed pure copper part is sintered to achieve this density. Sintering is the process of heating up a printed part to compact it. For most materials, sintering results in the shrinking of the part and inner dimensions must thus stay over a lower limit to avoid the closure of internal features."
The quality of the part was excellent and provides new opportunities for us commercialize to apply pulsating heat pipes. The heat pipe system was tested internally to verify the design both in terms of thermal and mechanical performance. Further experimental testing by the University of Palma.
We encourage you to delve deeper into the topic by reading Beamler's article.
Further reading:
Beamler ArticleWhat
Calyos is one of the world's leading experts in two-phase (liquid to vapour) heat transfer technologies. Calyos has developed a number of solutions for three specific cooling applications; power electronics, processors and batteries. Calyos also develops custom solutions beyond those applications for example, engine oil heat recovery. Calyos primarily targets the E-Mobility and Computing markets, where electrification and data processing are creating ever-rising demand for new, disruptive thermal solutions.
When
Calyos was incorporated in 2014 and is a spin-off from Euro Heat Pipes (EHP) who successfully developed similar two-phase technology for the space industry. EHP was incorporated in 2001 and today holds a majority market share in the European satellite market. Airbus D&S is now the majority shareholder in EHP. Calyos has been developing the technology for ground applications. This has involved a considerable amount of research and development, including developing flat evaporators, switching the working fluid to a dielectric green refrigerant and working on real-world applications such as those mentioned above.
Where
Calyos is based in Charleroi, Belgium. Calyos operates a factory side-by-side with our engineering team at this location and currently all of Calyos' production comes from this factory. Calyos supplies its products all across the world, including Asia, North America, Europe and South America.
Who
At Calyos we are a diverse group of talented individuals galvanised by the pursuit of establishing our disruptive, sustainable technology in our target markets. Remaining curious enables continued innovation as we work together to achieve our mission.
How
Calyos is built around four core values:
1. Applied Knowledge: Our technology is worthless unless we can get in it out there in the market. We strive to apply our knowledge and experience to real world applications.
2. Better Together: We succeed together. We view everyone from our customers to our shareholders as part of our team. Without working together we are nothing.
3. Inherent Flexibility: No thermal problem is the same. Therefore we strive to build flexibility into not only our solutions but also our working practices. This allows us to evolve with the market.
4. R-R-Research: Nothing stands still. As experts in our field, we must continue to innovate. We can then return to our first point and re-apply these innovations to real world applications.
Why
Our mission is to solve the greatest thermal challenges by enabling the adoption of the best, passive two-phase cooling solutions. Ensuring and delivering a sustainable approach to thermal management in the data-driven and electrified world we are creating.
Ben Sutton
Marketing & Business Development Manager
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