ToffeeX and partners develop innovative heat conduction technologies in 3D printing

A significant advance in the development of thermal management systems has been achieved through collaboration between ToffeeX, Imperial College London and the University of Wolverhampton. The Multiscale Optimization Framework for Aerospace Cold-Plates (MOfAC) project, supported by NATEP and Innovate UK, introduced new approaches to design and simulation using multiscale modelling and additive manufacturing with high-purity copper.

Traditional methods such as computational fluid dynamics (CFD) are reaching their limits due to high computational requirements and limited design iterations. The MOfAC project addresses this with an innovative multiscale modeling approach in which complex systems are divided into smaller, computable units. This method enables more accurate simulations in less time, allowing engineers to efficiently test more iterations and develop the best possible designs.

Another technical breakthrough of the project was the successful use of high-purity copper, which is particularly suitable for heat sinks due to its thermal conductivity, but was difficult to print. Using Laser Powder Bed Fusion (L-PBF) technology, the AMFM research team at the University of Wolverhampton was able to overcome these hurdles. Through improved energy utilization and process control, components were produced that combine thermal efficiency and sustainability.

Professor Arun Arjunan, director of the university’s Elite Centre for Manufacturing Skills (ECMS) and Centre for Engineering Innovation and Research (CEIR), said: “Working with ToffeeX, and Imperial College London pushing the boundaries of L-PBF copper printing and heat sink design highlights the potential of additive manufacturing and thermal management. By combining our expertise in advanced materials and 3D printing technologies, we will continue to develop innovative solutions that meet the growing demand for efficient thermal management systems across various industries.”

The results of the MOfAC project demonstrate the potential of generative design in combination with additive manufacturing. These approaches enable more efficient heat dissipation while reducing energy consumption and CO₂ emissions. Applications include aerospace, the automotive sector and hydrogen fuel cells.

Through close cooperation between research and industry, ToffeeX and its partners are setting new standards in thermal management and demonstrating how additive manufacturing and multiscale design can drive sustainable innovation.