HX3D: 3D Printed Heat Exchanger

Context

Space systems such as habitation modules, logistics modules, re-entry vehicles, and satellite platforms require complex active cooling systems. To date, the heat exchanger represents a critical component from a technical standpoint and is still underdeveloped by European companies involved in the space market. Thales Alenia Space, in collaboration with CIM, proposes the creation of a prototype heat exchanger that meets the needs of space missions by leveraging new technologies.

Solution

Through the use of Additive Manufacturing, a new model of heat exchanger has been designed and manufactured, fully meeting the requirements imposed by space missions and ensuring superior performance compared to traditional models. Thanks to the redesign of the design and geometries, testing, simulations, and the printing of a prototype, a highly innovative component has been obtained that is lightweight, compact, and high-performing, with highly efficient structures, significantly reducing weight and ensuring the thermal exchange performance targets.

Impact

The impact of the project translates into technological and industrial advancement, aimed at improving efficiency, simplifying production processes, and optimizing the component’s performance.

  • High-performance heat exchanger design
  • Elimination of welding processes
  • Weight reduction -40%
  • -25% pressure drops

Funded by the European Union – Next Generation EU

Client

Thales Alenia Space

Sector

Services

Technological area

Additive Manufacturing

Technologies

Laser Powder Bed Fusion (L-PBF)

Field Expertise

Design, Design for Additive, Thermofluid dynamic and structural simulation, Process Validation, Prototyping

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