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Press Release

Breakthrough in Two-Phase Cooling: First 3D-Printed Copper Pulsating Heat Pipe & New Reference Book

Location:

Charleroi, Belgium

DATE:

December 3, 2025
Breakthrough in Two-Phase Cooling: First 3D-Printed Copper Pulsating Heat Pipe  &  New Reference Book

In an important moment for the two-phase cooling community, two major advancements have put Pulsating Heat Pipes (PHPs) at the forefront of next-generation thermal management solutions:

  1. The first-ever 3D-printed copper PHP has been officially published in the ASME Journal of Thermal Science and Engineering Applications.
    -> The paper is available here
  2. A first Japanese book dedicated on PHPs has been released , highlighting the increasing global academic and industrial focus on this technology.
    -> Explore the book

These milestones show the rising maturity and innovation within PHP research and demonstrate  its viability in advanced cooling applications, especially for high heat flux electronic devices.

Innovative design and advanced manufacturing

The published research introduces a novel flat-plate PHP optimized for high-density thermal management. Key features include:

  • Spiral-shaped channels replacing traditional horizontal designs to enable both in-plane and out-of-plane heat spreading.
  • Additive manufacturing in pure copper using laser powder bed fusion—marking the first time a copper PHP has been 3D-printed.
  • Thermal performance optimized with methanol as the working fluid, achieving optimal filling ratios between 39% and 59%.
  • Superior results across all orientations, with thermal resistance reduced to less than half that of an empty PHP.

Designed to handle heat fluxes up to 50 W/cm², this new PHP demonstrates strong potential for integration into compact electronics, providing high-temperature uniformity in limited spaces, an essential requirement in high-performance, miniaturized systems.

A turning point for PHP technology

From academic research to manufacturing feasibility, these developments show the promising future of PHPs as a cornerstone in advanced thermal management. With global momentum building, new paths are opening for collaboration, industrialization, and application across electronics, automotive, aerospace, and beyond.

Interested in what’s next? We invite researchers, engineers, and innovators to connect and explore the next generation of two-phase cooling solutions.

Let's talk!

info@calyos-tm.com

Further reading:

Journal of Thermal Science and Engineering Applications

About Calyos

Who We Are
Calyos is a leader in the design and manufacture of two-phase thermal management systems. Building on our heritage from Euro Heat Pipes (EHP) and their space technology expertise, we specialize in innovative cooling solutions that tackle the thermal challenges of tomorrow.
What We Do
We engineer advanced cooling technologies, including loop heat pipes, micro-channel heat pipes, and pulsating heat pipes, to optimize thermal performance across a variety of applications. Typically these include: power electronics, processors, and batteries, but we don't stop there we are continuing to develop and produce fully customizable solutions for other specific needs, for example e-motors and fuel cells.
Where We Operate
Calyos is headquartered in Charleroi, Belgium, where our engineering and production teams work side by side in a state-of-the-art facility. From this base, we serve a global clientele, providing our cutting-edge solutions across North America, Asia, Europe, and South America.
When We Started
Calyos was incorporated in 2014 as a spin-off from Euro Heat Pipes (EHP), which was established in 2001 and has become a major player in the European satellite market. Since then, Calyos has been adapting and evolving EHP's space-grade cooling technologies for terrestrial applications.
Why We Matter
Our mission is to lead the industry towards adopting the most effective and sustainable thermal management solutions. We aim to address the most pressing thermal challenges in the data-driven and electrified environments of today, leveraging passive cooling technologies to achieve superior efficiency and environmental stewardship.
How We Succeed
Our success is driven by our commitment to four core values:
1. Applied Knowledge - Transforming deep technical expertise into market-ready solutions.
2. Better Together - Emphasizing collaboration with all stakeholders to enhance our collective success.
3. Inherent Flexibility - Adapting our solutions and practices to keep pace with evolving market demands.
4. Continuous Research - Persistently innovating to maintain our leadership in thermal technology.

Media contact

Ben Sutton
Marketing & Business Development Manager

ben.sutton@calyos-tm.com

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