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Beamler and Calyos successfully design and produced a 3D printed, pure copper pulsating heat pipe.
Beamler and Calyos successfully 3D printed a pure copper heat pipe (PHP or Pulsating Heat Pipe), proving the feasibility and effectiveness of such a project. This proof of concept marks a milestone in the production of PHP by additive manufacturing (AM).
As part of a recent research project analyzing pulsating heat pipes, Calyos chose Beamler as a partner to produce the 3D printed prototype. Beamler have since produced an article that aims to give an in depth analysis of the additive manufacturing of pure copper applied to heat pipes.
Here is an extract from the article:
"The device was 3D printed with pure copper using Laser Powder Bed Fusion (L-PBF). Pure copper has one the highest thermal conductivity of all metals, about 0.4 kW/(m.K) [2]. However, much higher thermal conductivity can be achieved with PHP up to 12 kW/(m.K) thanks to their working principles. The 3D printed pure copper heat pipe is a square prism of about 100 mm lengths for sides and 11 mm height. The images below show the blueprints and CAD model of the PHP. Internal dimensions of the channel are computed using internal software. The groove visible on the surface of the printed part are used for thermocouples. The total weight of the part is about 0.690 g. To prevent leakage of the working fluid and a loss of thermal conductivity, the part must be fully dense and the printed pure copper part is sintered to achieve this density. Sintering is the process of heating up a printed part to compact it. For most materials, sintering results in the shrinking of the part and inner dimensions must thus stay over a lower limit to avoid the closure of internal features."
The quality of the part was excellent and provides new opportunities for us commercialize to apply pulsating heat pipes. The heat pipe system was tested internally to verify the design both in terms of thermal and mechanical performance. Further experimental testing by the University of Palma.
We encourage you to delve deeper into the topic by reading Beamler's article.
Further reading:
Beamler ArticleWho We Are
Calyos is a leader in the design and manufacture of two-phase thermal management systems. Building on our heritage from Euro Heat Pipes (EHP) and their space technology expertise, we specialize in innovative cooling solutions that tackle the thermal challenges of tomorrow.
What We Do
We engineer advanced cooling technologies, including loop heat pipes, micro-channel heat pipes, and pulsating heat pipes, to optimize thermal performance across a variety of applications. Typically these include: power electronics, processors, and batteries, but we don't stop there we are continuing to develop and produce fully customizable solutions for other specific needs, for example e-motors and fuel cells.
Where We Operate
Calyos is headquartered in Charleroi, Belgium, where our engineering and production teams work side by side in a state-of-the-art facility. From this base, we serve a global clientele, providing our cutting-edge solutions across North America, Asia, Europe, and South America.
When We Started
Calyos was incorporated in 2014 as a spin-off from Euro Heat Pipes (EHP), which was established in 2001 and has become a major player in the European satellite market. Since then, Calyos has been adapting and evolving EHP's space-grade cooling technologies for terrestrial applications.
Why We Matter
Our mission is to lead the industry towards adopting the most effective and sustainable thermal management solutions. We aim to address the most pressing thermal challenges in the data-driven and electrified environments of today, leveraging passive cooling technologies to achieve superior efficiency and environmental stewardship.
How We Succeed
Our success is driven by our commitment to four core values:
1. Applied Knowledge - Transforming deep technical expertise into market-ready solutions.
2. Better Together - Emphasizing collaboration with all stakeholders to enhance our collective success.
3. Inherent Flexibility - Adapting our solutions and practices to keep pace with evolving market demands.
4. Continuous Research - Persistently innovating to maintain our leadership in thermal technology.
Ben Sutton
Marketing & Business Development Manager
