PWR and Eplus3D partnership brings advanced cooling solutions through Additive Manufacturing

June 28, 2024

June 28, 2024

Eplus3D has outlined its partnership with PWR in the production of heat exchangers and supporting components (Courtesy Eplus3D)
Eplus3D has outlined its partnership with PWR in the production of heat exchangers and supporting components (Courtesy Eplus3D)

In a recent case study, Eplus3D, based in Hangzhou, China, detailed the use of its Additive Manufacturing technology by PWR Advanced Cooling Technology, a global company and manufacturer focused on high-complexity, small-batch customised heat exchangers and supporting components, which are specially designed for motorsport and aerospace application, headquartered in Ormeau, Australia.

On its journey to adopt Additive Manufacturing technology, PWR conducted an evaluation of AM machines from a variety of companies.

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“We provided the same challenge to all the vendors, and Eplus3D stood out,” stated Toby Maconachie, Additive Manufacturing Engineer at PWR. “They not only delivered the test part the fastest, but their test part also passed rigorous pressure and leak tests, demonstrating exceptional stability and reliability. Furthermore, Eplus3D excelled in external surface finishing, achieving a design with leak tight thin tube walls and fine fin geometry, with consistently high print quality and minimal iterations required. These were the deciding factors for us to choose Eplus3D.”

Aheadd CP1 as a requirement

Aheadd CP1 is an aluminium-iron-zirconium powder solution designed specifically for Additive Manufacturing without volatile elements, rare earths, silicon or ceramic particle additions. Aheadd CP1 was approved by the Federation Internationale de l’Automobile (FIA) for use in Formula 1 racing beginning in the 2024 season.

In response to PWR’s decision to use the high-performance aluminium powder Aheadd CP1, Eplus3D worked with the company to develop optimised process parameters. The optimisation process enables parts to be manufactured at an average density of 99.93%. This is in combination with the as-built properties of Aheadd CP1, which offers high ductility and the possibility of producing large components with minimal geometric deformation.

Deepening collaboration

As the collaboration with Eplus3D deepened, PWR reported its use of the company’s Additive Manufacturing has enabled quick and economical product design and manufacturing capabilities, allowing PWR to meet complex client demands.

Maconachie stated, “This improvement in capability has brought us unexpected gains. By showcasing our diverse capabilities and tailored solutions, we inspire confidence in our customers, fostering long-term collaboration and a reliable brand reputation.”

“The aerospace industry, especially in the realm of electronics cooling, is presenting new opportunities,” Maconachie added. “Meanwhile, in the context of evolving technologies, we’re seeing a shift towards more sophisticated cooling systems.”

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June 28, 2024

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