Alloyed Introduces 3D Printed Copper Cooling Plate »3dpbm

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Ally recently introduced an additively manufactured copper cooling plate. The unique piece was on display at Formnext and recently featured in the Cool Parts Show video series. Born from the merger of Betatype and Oxmet Technologies at the end of 2019, Alloyed offers a unique and complementary stack of technologies for the manufacture of advanced metal components by additive manufacturing and traditional means. The 3D printed cooling plate was made possible through the use of copper powders for better printability developed in collaboration with JXNMM.

The company has developed and uses a proprietary calculation platform and advanced material modeling to identify the right alloy composition for any application and process. This is combined with Alloyed Engine technology specifically for AM, with the ability to deliver higher quality parts faster and more cost effectively for a wide range of applications. The company’s turnkey solution provides technology at all scales, from alloy composition, materials engineering and part design to scale for series production. The cooling plate is an example of what can be done when optimized AM geometry is combined with optimized AM material properties ”.

The copper cooling plate is specially designed for use in data centers and, as a liquid cooling system, can have a significant impact on reducing power consumption compared to conventional air cooling methods . AM is the ideal technology for fabricating cooling plates, as more complex geometries can be produced at lower cost and with superior functionality and performance, both in terms of heat exchange and liquid pressure drop. . The unibody nature of the add-on part results in a simpler and more efficient component that outperforms traditionally assembled cold plates. Due to the reduced assembly requirements, parts are also easier to install and
have lower maintenance needs.

However, copper is a notoriously difficult metal to process in AM due to the high thermal conductivity of the melt (the very reason it is an ideal material for plate cooling) and its high natural reflectivity. JX Nippon Mining & Metals (JXNMM) and Alloyed have partnered to offer a comprehensive portfolio of laser bed smelting solutions for copper and its alloys. JXNMM has developed copper powders with improved printability, allowing the production of parts with very low porosity and electrical conductivity. This is achieved through a new surface treatment which adds an anti-oxidant effect and prevents an increase in the oxygen content. For electron beam processes, the surface treatment inhibits sintering of the powder (thereby increasing design flexibility) and the surface treatment can also be used to increase absorption capacity in laser beam systems. The powder can achieve relative densities> 99.95% using the electron beam method and 99.91% using the laser bed method.

Alloyed presents a 3D printed pure copper cooling plate created in collaboration with JXNMM, using copper powders with improved printability

Enrique Alabort, Co-Founder of Alloyed and Director of Alloyed Japan, said: “The success of the copper cooling plate presented at Formnext is due to the combined expertise of Alloyed and JXNMM. The materials developed by JX allow Alloyed to use its proprietary engine and architect software to produce the complex high-fidelity geometries and lattice structures of the cooling plate. Alloyed specializes in producing components with fine characteristics and can produce thin walls up to an average thickness of 190 microns, and its design expertise for AM allows it to make the most of the design freedom afforded by the Alloyed. process. This expertise is clearly illustrated in the design and production of the copper liquid cooling plate ”.

Alloyed has a compelling offering for optimizing advanced digital metal fabrication applications and is committed to further improving high performance components and processes for its customers. Joining the Alloys-By-Design (ABD) brand with Betatype and a factory that makes parts – Alloyed Digital Manufacture (ADM) – and partnering with expert material developers like JX means Alloyed can offer its customers the development of superior and customized alloys, unprecedented levels of process control and advanced performance, and expert metal AM production capabilities from application development to production. Alloyed thus provides its customers with a range of expertise and additional services that optimize the production of metal parts through digital manufacturing.

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