3D Printing Liquid Cooling Technology
1. Development Trends of Liquid Cooling Technology and Current Status of 3D Printing Liquid Cooling Technology
Currently, liquid cooling technology is in its application infancy globally, especially in the IT industry, primarily used in supercomputing and high-performance computing fields. In the past, liquid cooling technology was mainly based on immersion cooling, which was considered an ideal form of liquid cooling due to its direct contact with the coolant, fanless operation, and high heat exchange efficiency. However, as GPU chip power continues to rise, with single chips generating over 1000 watts and potentially reaching 1800 watts in the future, significant uneven heating characteristics are observed in high-performance computing devices, exposing issues with traditional immersion cooling in terms of heat dissipation balance. Additionally, immersion cooling has been found unsuitable for long-term use due to mechanical fatigue caused by temperature fluctuations, leading to solder joint failures. Currently, the mainstream technology is unidirectional cold plate liquid cooling, which has advantages such as industry chain support, high engineering feasibility, and suitability for large-scale deployment, making it the mainstream choice in the high-performance computing field. Furthermore, phase change cold plates and hybrid liquid cooling are emerging technologies that, while offering higher heat exchange efficiency or comprehensive cooling capabilities, are still in the experimental stage and have not yet achieved commercial viability. Unidirectional cold plates still have development potential, and their performance can be further enhanced by reducing thermal resistance, minimizing flow resistance, and lowering inlet water temperature. Currently, the inlet water temperature can be reduced to as low as 25 degrees, effectively improving cooling capacity. Overall, unidirectional cold plates are expected to dominate in the foreseeable future, while other technologies will be developed as backup solutions.
2. Current Applications of 3D Printing Liquid Cooling Technology in Microchannel Processing and Progress of Leading Manufacturers
The main application scenario of 3D printing technology in liquid cooling systems is the processing of microchannels, where its advantage lies in the ability to create complex shapes that are difficult to achieve with traditional CNC machining. Through additive manufacturing methods such as Selective Laser Sintering (SLS), 3D printing can construct biomimetic structures for flow channels, which exhibit curved shapes similar to natural rivers, resulting in lower flow resistance and more uniform thermal resistance distribution, significantly enhancing the cooling capacity of cold plates. Current experimental data shows that cold plates produced by 3D printing can achieve a water flow rate of up to 150 liters per unit time, effectively cooling heat sources of up to 4000 watts. This experiment was conducted by QIT, and while it is not an engineered product, it demonstrates the potential of this technology in extreme cooling capabilities (for more real-time updates, add WeChat: aileesir). To achieve engineering applications, two issues need to be addressed: reducing flow resistance within the channels and improving processing accuracy to a microscopic scale of 50 microns while ensuring yield and process stability. Currently, the application of 3D printing in the liquid cooling field is still in the stage of process breakthroughs and has not yet entered large-scale data centers or high-performance computing fields.
3. High-Precision Microchannel Processing Technology for Copper Materials and Its Industrial Chain Capabilities
Currently, there are companies capable of high-precision microchannel processing technology for copper materials. The American company OLLE employs a stacking process using ultra-thin copper sheets for processing and has made relevant information public. This technology is based on the innovative combination of laser sources and machine tool equipment, achieving 50-micron precision processing of copper materials, with a significantly higher yield than traditional CNC machining. Technically, this process requires matching appropriate light sources to different materials and possesses a high degree of customization in equipment development, forming certain technical barriers. Additionally, early entrants have advantages in equipment development, process methods, and mastery of light sources, making their technology paths difficult to replicate and providing strong supply chain positioning capabilities. In the Chinese mainland supply chain, companies with advanced processes, stable production capacity, and material advantages are more likely to occupy leading positions. The application of 3D printing technology in this field still faces challenges such as light source precision, process consistency, and equipment specialization, and is currently mainly applied to specialty products or consumer products, without achieving large-scale mass production. For microchannel cold plate structures, whether to adopt a 3D printing route and the corresponding value level still need further verification of supply chain maturity.
4. Business Models of Processing Technology and Cost Control in Aerospace and Consumer Goods Fields
In the aerospace and consumer goods fields, processing technology and cost control present distinctly different business models. Aerospace products are characterized by high customization, high precision, and small batch sizes, primarily used for special purposes, requiring high demands for processing efficiency, yield, and technical barriers. In the aerospace sector, companies face the choice of transforming from equipment suppliers to service providers, which means providing a full set of solutions, including customized services and end-to-end delivery, thereby integrating more deeply into the industry chain and forming higher industry barriers.
The cost of the processing industry is closely related to scale; for example, products like quick connectors and cold plates are initially expensive, but as production scales up, unit costs decrease significantly. Material costs are not the only determining factor; processing scale and capacity utilization have a greater impact on the overall cost structure. If a company can achieve saturated production in a short period, it can effectively reduce marginal costs and enhance profitability. In the liquid cooling system field, its value proportion in intelligent computing systems is less than 5%, so cost is not a primary consideration; the focus is on its role in ensuring the stable operation of IT equipment. By improving cooling efficiency, the lifecycle of the existing mature supply chain can be extended, avoiding the high costs associated with switching technology routes.
In terms of technology application, it depends on which processes can achieve large-scale production. For high-power cooling issues, temporary solutions can be flexibly implemented, such as using wide cabinets instead of standard cabinets to reduce engineering implementation difficulties. This approach not only increases connection density but also enhances system performance, even outperforming certain standards. The entry of technology does not rely on specific timing but depends on whether a company has the capability to achieve scale and solve current problems. As long as the technology is adequately prepared, it can enter applications at the appropriate stage without waiting for a specific product iteration. Additionally, certain technologies, such as HVDC (High Voltage Direct Current), can be widely applicable in the range of 200kW to 1MW, not limited to specific power levels, with its value lying in the construction and promotion of ecosystems.
5. Technical Challenges and Application Prospects of 3D Printing in Cold Plate Manufacturing
The challenges of 3D printing in cold plate manufacturing lie in processing precision, material compatibility, and large-scale production. First, 3D printing must achieve precision levels exceeding those of CNC processing and be capable of processing complex structures to enable mass application. Secondly, materials must be processed using the same material, which is a critical technical node. In terms of equipment, the entire process must be mature and scalable to ensure stable yield during mass production, thus possessing mass production capability. Cost-wise, the comparison between 3D printing and CNC depends on complexity. For simple structures, CNC has a significant cost advantage; for complex structures, 3D printing has advantages in processing efficiency and process paths. Its value lies in breaking boundaries and solving complex structural problems that traditional processing methods cannot achieve. Currently, companies in the United States have conducted product validations and launched relatively mature solutions, while domestic manufacturers are also actively validating, but overall, it is still in the stage of striving for progress. Additionally, the industrialization challenges of 3D printing technology also involve matching materials with light sources, especially in copper alloy printing, where technical bottlenecks still exist and need to be gradually overcome.
6. Material and Process Challenges and Industrial Value of 3D Printing Cold Plates
The application of 3D printing in cold plate manufacturing faces challenges in material and light source matching, thermal conductivity enhancement, and processing precision. Currently, copper remains the optimal choice for thermal conductivity, with natural copper cold plates having a thermal conductivity of up to 3000W/(m·K), while diamond copper alloys can theoretically reach 6000W/(m·K). However, their thermal resistance increases during repeated high and low-temperature cycles, leading to insufficient stability. The processing challenges of copper alloys lie in the matching of material properties and processing techniques, which have not yet been fully overcome. Therefore, it is recommended to prioritize solving the processing issues of copper materials before advancing the application of copper alloys. In the 3D printing field, the value assessment of cold plates shows that the price of copper cold plates abroad is about $300/kW, while domestically it is about $100/kW. The processing precision of microchannel cold plates directly affects costs; the smaller the channel and the higher the precision, the lower the yield and the higher the cost. 3D printing cold plates involve material costs, processing difficulties, and process precision, especially in high thermal load scenarios such as servers, where performance requirements for cold plates are even higher. Baiyite, as a leading domestic metal 3D printing company, has a competitive advantage among North American clients like Apple in the 3C sector. If 3D printing cold plate systems achieve large-scale mass production in the future, Baiyite will have strong competitiveness due to its technology, scale, and business capabilities.
Q&A
Q: What are the main issues currently facing liquid cooling technology in the intelligent computing field?
A: The main issue currently facing liquid cooling technology in the intelligent computing field is uneven heat dissipation. Due to the extremely high and concentrated heat generation of GPU chips, traditional immersion cooling cannot target localized high heat sources, leading to temperature discrepancies on the same board. This temperature fluctuation can cause inconsistent thermal expansion coefficients, resulting in thermal expansion and contraction effects, causing mechanical fatigue and ultimately leading to solder joint failures, affecting system stability and lifespan. Therefore, immersion cooling shows certain limitations in intelligent computing scenarios, prompting the industry to shift towards more suitable unidirectional cold plate liquid cooling technology.
Q: What is the current development status of 3D printing liquid cooling technology in the industry?
A: 3D printing liquid cooling technology is still in its emerging stage and has not yet become mainstream. Although 3D printing has advantages in manufacturing complex structures and customized cold plates, enhancing the flexibility and heat exchange efficiency of internal flow channels, its maturity in the liquid cooling industry chain still needs verification. Currently, leading manufacturers are taking a wait-and-see and research attitude towards 3D printing liquid cooling technology, mainly using it for exploratory and technical reserve purposes in laboratory stages. Due to challenges involving materials, processes, sealing, and cost control, achieving large-scale commercial use of 3D printing liquid cooling technology will still require time to refine. At this stage, the industry is more inclined to prioritize advancing unidirectional cold plate technology, which has mature industry chain support, while 3D printing liquid cooling is being researched as a potential supplementary solution.
Q: What are the advantages of 3D printing technology in liquid cooling systems?
A: The advantages of 3D printing technology in liquid cooling systems lie in its ability to create complex shapes that are difficult to achieve with traditional CNC machining, especially in the construction of microchannels. Through additive manufacturing methods such as Selective Laser Sintering, 3D printing can produce flow channels with biomimetic structures, exhibiting curved shapes similar to natural rivers, resulting in lower flow resistance and more uniform thermal resistance distribution, significantly enhancing the cooling capacity of cold plates. This method breaks through the structural limitations of traditional processing, allowing cold plates to carry higher water flow rates within a unit time, thus achieving stronger cooling capabilities.
Q: Which companies are currently leading in the field of 3D printing liquid cooling technology?
A: Currently, the application of 3D printing liquid cooling technology is still in the process of technological breakthroughs and has not yet entered large-scale data centers or high-performance computing fields. From an industry chain perspective, leading domestic companies in the 3D printing field include Baiyite, which primarily produces laser equipment (for more real-time updates, add WeChat: aileesir) and has a six-head laser system, but still faces certain limitations in processing precision. Additionally, Southern Additive also possesses relevant manufacturing capabilities, but its process maturity and whether it meets customer needs remain unclear. Internationally, American companies have achieved high-precision microchannel processing capabilities on thin foils and have integrated them into cold plates, demonstrating higher technical levels. Meanwhile, non-listed companies like Zhongshan Lijian are also exploring the application of 3D printing in structural component processing, but their main clients are concentrated in the consumer electronics sector and have not yet delved deeply into liquid cooling technology research.
Q: What role does the light source play in processing precision and material compatibility in current copper material microchannel processing technology?
A: The light source plays a decisive role in copper material microchannel processing. Different materials have different wavelength requirements for light sources. Due to copper’s high reflectivity and strong thermal conductivity, higher frequency lasers, such as green light or more advanced ultraviolet and extreme ultraviolet sources, are required to achieve 50-micron high-precision processing. The precision of the light source directly affects the uniformity of sintering and processing consistency, which are factors in process stability and product yield. Additionally, the customized configuration of the light source and laser head also determines the specificity of the equipment and the technical barriers, thereby affecting the market competitiveness of enterprises.
Q: How do companies build technical barriers and gain supply chain advantages in the current copper material high-precision processing industry chain?
A: Companies build technical barriers in high-precision copper material processing mainly through three aspects: mastery of light source technology, including laser wavelength, power, and stability; innovation in processing methods, such as using stacking technology instead of traditional powder sintering to improve precision and consistency; and directional development of equipment, customizing dedicated processing centers that integrate laser heads, raw materials, and control systems. Companies with these capabilities not only form barriers at the technical level but can also gain first-mover advantages by entering the market early, creating a competitive position that is difficult to replicate. In the supply chain, companies with advanced processes, large-scale production capacity, and material advantages are more likely to occupy leading positions, especially in the consumer electronics and high-end specialty application fields, where they possess strong profitability.
Q: What are the differences in processing technology and cost control between the aerospace and consumer goods fields?
A: Aerospace products are characterized by high customization, high precision, and small batch sizes, emphasizing technical barriers and yield, with products primarily used for special purposes, thus requiring high demands for processing efficiency and process requirements. In contrast, the consumer goods field focuses on large-scale production, with relatively lower economic requirements and greater tolerance, emphasizing the cost advantages brought by scaling. Aerospace companies also face the choice of transforming from equipment suppliers to service providers, which means providing a full set of solutions, including customized services and end-to-end delivery, thereby integrating more deeply into the industry chain and forming higher industry barriers.
Q: Why is cost not a consideration for liquid cooling systems in intelligent computing systems?
A: The value proportion of liquid cooling systems in intelligent computing systems is less than 5%, so cost is not a primary concern. Its value lies in providing stable cooling assurance for IT equipment, enhancing system operational efficiency and reliability, thereby extending the lifecycle of the existing mature supply chain. Due to the high costs associated with switching technology routes, the role of liquid cooling systems is more of a “safeguarding” nature, ensuring the stable operation of IT services. Therefore, even if there is a certain cost increase, as long as it brings improvements in cooling performance, the supply chain is generally acceptable.
Q: What are the technical advantages and cost differences of 3D printing in cold plate manufacturing compared to CNC processing?
A: The main advantages of 3D printing in cold plate manufacturing compared to CNC processing lie in its ability to process complex structures. CNC has significant cost and efficiency advantages in simple structure processing, but when faced with complex structures requiring multiple processing steps, 3D printing is more efficient and can achieve integrated forming of three-dimensional, rotating, and spatial structures. The value of 3D printing lies in breaking boundaries, making innovations that were previously impossible due to processing limitations feasible. In terms of cost, the comparison between 3D printing and CNC is not linear; CNC excels in simple structures, while the cost disadvantage of 3D printing for complex structures diminishes or even reverses. Therefore, 3D printing is more suitable for applications requiring high freedom and complex cooling structures.
Q: What is the current progress of industrialization verification of 3D printing cold plates domestically and internationally?
A: Currently, there have been certain industrialization verification results for 3D printing cold plates abroad, with American companies launching relatively mature products and entering practical application stages. These companies have not only completed technical validation but are also exploring applications in high-density cooling scenarios such as data centers. In contrast, domestic manufacturers are also actively conducting relevant verification work, but overall, they are still in the promotion stage and have not formed large-scale applications. Downstream users are open to 3D printing technology and view it as an important path to break through traditional processing limitations. Although there are no publicly available mature products in the domestic market yet, both upstream and downstream of the industry chain are continuously investing in research and testing. Meanwhile, the industrialization challenges of 3D printing still focus on material compatibility, equipment stability, and process maturity, requiring further breakthroughs in technologies such as copper alloy printing.
Q: What are the main technical difficulties faced by 3D printing cold plates in material selection?
A: The main technical difficulties faced by 3D printing cold plates in material selection include material and light source matching, thermal conductivity enhancement, and thermal stability issues. Copper remains the optimal material for thermal conductivity, with natural copper thermal conductivity reaching 3000W/(m·K), while copper alloys like diamond copper can theoretically reach 6000W/(m·K). However, their thermal resistance increases during repeated high and low-temperature cycles, leading to insufficient stability. The processing challenges of copper alloys lie in the matching of material properties and processing techniques, which have not yet been fully overcome. Therefore, it is recommended to prioritize solving the processing issues of copper materials before advancing the application of copper alloys.
Q: What is the industrial value and market pricing mechanism of 3D printing cold plates?
A: The industrial value of 3D printing cold plates is significantly influenced by material costs, processing difficulties, and process precision. The price of copper cold plates abroad is about $300/kW, while domestically it is about $100/kW. Microchannel cold plates require high processing precision; the smaller the channel and the higher the precision, the lower the yield and the higher the cost. Cold plates include not only the material itself but also the costs of processing, connection structures, and overall module manufacturing. In high thermal load scenarios such as servers, the performance requirements for cold plates are even higher, further affecting their value assessment. Therefore, the value of 3D printing cold plates depends not only on materials but also closely relates to manufacturing processes and application scenarios.
Disclaimer: The above content does not constitute investment advice, and any losses incurred based on this as an investment basis are not the responsibility of the author.
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