COPPER 3DP publishes design guide for copper Additive Manufacturing
COPPER 3DP, a division of Suzhou Como Precision Materials Co., Ltd., based in Suzhou, Jiangsu, China, has published a practical guide outlining key considerations when designing pure copper and CuCrZr components for Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing.
According to the company, copper Additive Manufacturing is particularly well suited to applications where it can integrate complex cooling channels, reduce part count or enable geometries that would be difficult or uneconomical to produce using conventional manufacturing methods.
Copper’s high reflectivity and thermal conductivity require designers to adopt a process-specific approach from the earliest stages of component development, states COPPER 3DP. The guidance is aimed at applications including cold plates, compact heat exchangers, induction coils, busbars, RF and vacuum hardware, semiconductor thermal management components and conformal cooling inserts.
COPPER 3DP advises selecting materials based on application requirements rather than on alloy designation alone. Whilst pure copper is recommended where maximum thermal or electrical conductivity is required, CuCrZr and CuCr1Zr alloys may be better suited to components that also require higher mechanical strength, wear resistance or dimensional stability under repeated thermal cycling.
A significant focus is placed on the design of internal cooling channels. The company recommends considering powder removal, inspection access and testing requirements during the design stage, noting that long blind channels and enclosed cavities can be difficult to clean and inspect after manufacture. It also advises using gradual channel transitions and incorporating machining allowances on sealing surfaces, precision interfaces and threaded features.
The publication also highlights the importance of considering the complete manufacturing route before production begins. Depending on the application, this may include heat treatment, support removal, wire EDM, CNC machining, surface finishing, cleaning, leak testing and dimensional inspection. COPPER 3DP adds that providing comprehensive RFQ documentation, including CAD models, engineering drawings, material specifications and critical quality requirements, can help streamline production planning.
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