As server architectures become increasingly power-dense and AI workloads grow more demanding, traditional cooling systems are reaching their physical and economic limits. Alloy Enterprises has introduced a direct liquid cooling (DLC) system made of copper, based on its proprietary Stack Forging manufacturing process. This technique enables monolithic construction of complex heat sink structures with micro-channeled internal geometries, specifically tailored to the thermal hotspots of modern data center hardware.
The Stack Forging technology uses controlled layering and consolidation of metal materials, providing an alternative to conventional joining methods that often introduce potential leak points through seals or fasteners. For liquid cooling applications, this results in a robust, low-maintenance design with high thermal efficiency. According to Alloy Enterprises, their new copper components reduce pressure drop by a factor of ten, allowing the use of smaller pumps and enabling cooling water temperatures of up to 44°C. This significantly reduces the energy required for active air conditioning.
“Alloy Enterprises is setting a new standard in direct liquid cooling technology with our proprietary Stack Forging process,” said Ali Forsyth, PhD., CEO and Co-founder of Alloy Enterprises. “We now deliver industry-leading thermal performance in both aluminum and copper, enabling higher rack densities, significant cost savings and greater sustainability. With 600 kW racks on the horizon, the shift to liquid cooling is no longer optional—it’s mission-critical.”
Given projections that data center power demand could triple by 2030, Stack-Forged components aim to unlock new efficiency reserves.
“Alloy’s copper line is already showing promising results in early customer deployments,” added Forsyth. “These components are hitting target thermal resistance thresholds while maintaining exceptional pressure drop performance, even in the most demanding rack configurations.”
Alloy Enterprises is now shipping its copper cooling solutions, positioning itself in a rapidly evolving market that is increasingly dependent on direct liquid cooling technologies.
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