LONDON, December 2024—ToffeeX, in partnership with Imperial College London and the University of Wolverhampton, have achieved a groundbreaking milestone in heat sink design through the innovative use of multiscale modeling and high-purity copper additive manufacturing (3D printing).
Please refer to our joint press release about the MOfAC Project to and our blog article to learn more.
Backed by NATEP and Innovate UK, the “Multiscale Optimisation Framework for Aerospace Cold-Plates (MOfAC) Project” is set to transform thermal management systems by demonstrating a new approach to design and simulation. This milestone celebrates the successful completion of the 14-month project that began in September 2023. The multiscale modeling framework is reshaping what’s possible in engineering, providing faster, better, and greener solutions for thermal management.
A new era of thermal management
Traditional computational fluid dynamics (CFD) falls short
CFD has been a key tool in thermal management, but it faces significant challenges:
- High computational demands: Complex simulations require powerful hardware and long processing times.
- Limited design iterations: Slow processing restricts how many iterations can be explored.
- Accuracy trade-offs: Engineers often compromise on resolution to save time, risking suboptimal designs.
The MOfAC project has introduced the multiscale modeling framework, which addresses these challenges by rethinking how thermal systems are simulated. Instead of modeling an entire system in one go, it breaks the problem into smaller, manageable units called “unit cells.”
Unlike traditional CFD, multiscale modeling reduces design time while maintaining exceptional accuracy. This efficiency allows engineers to iterate faster and explore broader design possibilities with unmatched speed and precision.
Additionally, leveraging high-purity copper—a material renowned for its thermal conductivity but historically difficult to 3D print—the University of Wolverhampton has employed advanced Laser Powder Bed Fusion (L-PBF) technology to produce the first-ever specimen using the new multiscale modeling framework.
Efficiency meets sustainability in multiscale modeling
Benefits include:
- Unparalleled computational efficiency: Multiscale modeling reduces the need for high-powered systems while accelerating design cycles.
- Superior performance: Heat sinks designed with this framework deliver exceptional thermal efficiency and durability and can be used in hydrogen fuel cells, advanced electronics, aerospace cooling systems, and more.
- Sustainability: Multiscale modeling aligns with global carbon reduction and sustainable engineering goals by optimizing energy use and delivering more effective cooling.
ToffeeX is proud to lead this innovation in collaboration with Imperial College London and the University of Wolverhampton. This partnership exemplifies the power of interdisciplinary teamwork, where cutting-edge manufacturing and research expertise merge to address critical engineering challenges. Multiscale modeling and copper 3D printing capabilities are reshaping what’s possible in engineering, providing faster, better, and greener solutions for thermal management.
Nicholas Raske, Senior Engineer, ToffeeX
Pioneering innovation in copper additive manufacturing
Copper’s exceptional thermal properties make it ideal for heat sinks, but its high reflectivity and tendency to oxidize have historically posed challenges for additive manufacturing. High reflectivity reduces energy absorption during laser-based processes, while oxidation can degrade material quality.
The University of Wolverhampton’s AMFM Research Group has tackled these issues using advanced laser technology and beam-shaping techniques. By improving energy absorption and ensuring precise process control, they’ve enabled the scalable production of high-performance copper components, setting a new benchmark in additive manufacturing.
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.
Professor Arun Arjunan, University of Wolverhampton
Transforming industries with generative design
The MOfAC project showcases the game-changing potential of physics-driven generative design. ToffeeX’s advanced algorithms and the multiscale framework allow engineers to achieve optimal designs faster, driving efficiencies across multiple industries.
Integrating multiscale modeling with copper 3D printing also marks a breakthrough. It delivers improved heat transfer performance while reducing energy demands. By innovating with pure copper designs, engineers can achieve superior thermal efficiency and significantly lower CO2 emissions, advancing the transition to a more sustainable future.
Driving the future of thermal management
This collaboration is an exciting step forward for thermal management solutions, making them more efficient, sustainable, and scalable for industries like aerospace, automotive, and energy. It’s a true team effort, bringing together the unique strengths of academia, industry, and research to achieve something greater than the sum of its parts.
ToffeeX and its partners remain committed to advancing sustainable solutions and fostering the next generation of thermal management technologies.
About the University of Wolverhampton
The University of Wolverhampton’s AM experience and history spans over two decades. The University was the first UK institution to install a laser-based AM machine circa 1999, and since then has been at the forefront of metal AM development. Recently, the University’s additive manufacturing of functional materials (AMFM) research group and spin-out Additive Analytics has capitalized on this experience and knowhow developing proprietary data-driven laser powder bed fusion parameters enabling 3D printable anti-Covid materials, high purity copper and silver and winning the 2022 Emerald Literati Award.
About Imperial College
Prof Rob Hewson and Prof Matthew Santer lead the metamaterials research group in the Department of Aeronautics. The group has expertise in designing metamaterials for structural, vibration, thermal, and fluidic applications. This active area of research allows the team to design structures for a range of applications using formal optimization methodologies. Examples of previous research activity include the design of lightweight structures with vibration responses that can avoid key frequencies or modes and designing shells and morphing structures that deform in a prescribed way to external loading.
About the National Aerospace Technology Exploitation Programme (NATEP)
The National Aerospace Technology Exploitation Programme (NATEP) is a UK-based initiative aimed at fostering innovation and collaboration in the aerospace sector. By supporting small and medium-sized enterprises in developing technologically advanced products for the aerospace industry, NATEP helps maintain and grow the UK’s position as a leader in aerospace technology on the global stage, ensuring that the sector remains competitive and sustainable.
About ToffeeX
ToffeeX is the leader in physics-driven generative design. Their AI-powered software uses physics to guide the design process, empowering engineers to create optimized products that meet all their requirements in a matter of hours. The world’s leading engineering organizations use ToffeeX to accelerate their path to sustainability and is at the forefront of innovation in additive and traditional manufacturing processes.