Thermal management systems are becoming more compact, more efficient, and more integrated into mission-critical equipment across aerospace, energy, automotive, and industrial applications. Traditional manufacturing limits the internal geometries and performance characteristics of heat exchangers, often resulting in heavier, bulkier, or less efficient designs.
AltForm enables manufacturers to overcome these limitations with Powder Bed Fusion, advanced laser processes, automation, and intelligent software. Our solutions support the development and production of heat exchangers with enhanced thermal performance, reduced size and weight, and optimized internal structures that are not achievable with conventional methods.
Complex internal geometries for improved thermal transfer
Powder Bed Fusion allows manufacturers to transition directly from CAD to highly optimized components with internal channels, lattice structures, and multi-layered flow paths. These geometries significantly improve heat transfer efficiency, reduce pressure drop, and enable compact, high-performance designs.
AltForm’s Print 300 and Print 400 platforms deliver the precision required for consistent and repeatable thermal performance, supporting applications where even minor variations affect efficiency and reliability.
Typical use cases include:
- ultra-lightweight heat exchangers for aerospace systems
- compact cooling modules for electric and hybrid powertrains
- thermal management components for industrial processes and high-power electronics
- high-efficiency heat exchangers for energy and oil and gas equipment
Size and weight reduction through additive design
Additive manufacturing eliminates many of the geometric constraints that limit conventional heat exchanger design. By consolidating multiple assemblies into a single printed component, manufacturers can:
- reduce mass while maintaining structural integrity
- shorten flow paths for improved thermal performance
- remove the need for complex welding or brazing
- minimize leakage risks and improve overall reliability
These benefits are especially valuable in applications where space and weight directly impact system efficiency, performance, or cost.
Materials engineered for thermal performance
AltForm supports a wide range of materials suited for heat exchanger production, including high-conductivity aluminum and copper alloys, nickel-based superalloys, titanium, and stainless steels.
These materials are processed with consistent quality, enabling reliable performance in demanding environments.
Our platforms ensure controlled thermal behavior, repeatability, and uniformity across complex structures, supporting qualification and certification for high-performance applications.
Digital control and intelligent production
AltForm’s software ecosystem integrates fleet management, monitoring, predictive maintenance, and data governance, giving manufacturers full visibility into production conditions.
With the support of our AI-enabled assistant, operators receive guidance on setup, optimization, troubleshooting, and maintenance.
This digital layer improves usability, reduces downtime, and ensures stable production of heat exchangers with intricate geometries and tight performance tolerances.
Enabling next-generation thermal management
Thermal efficiency is a critical factor across industries, and manufacturers need solutions that increase performance while reducing size, weight, and production complexity.
AltForm supports this evolution by delivering additive and laser-based technologies that translate advanced thermal designs into stable, repeatable, and industrial-ready production workflows.
Our solutions to realize high-performance heat exchangers
Print 200 Series
Print 300 Series
Print 400 Series
