Conflux Technology designs, engineers, and produces additive manufactured heat exchangers for a variety of thermal challenges in multiple industries. Recently, they unveiled a collaboration with AMSL Aero, an Australian aircraft manufacturer involved in building the world’s most efficient long-range zero emissions electrical VTOL aircraft. 

Also from EE: Electric Race Car Uses 3D-Printed Components

Under the first phase of the project to develop hydrogen fuel cell cooling for AMSL Aero’s Vertiia VTOL aircraft, Conflux developed three heat exchanger concepts, each focusing on minimizing weight and volume while managing continuous heat loads and reducing drag. The ultimate goal was to enable flight distances of up to 1,000 km.

Already at its second phase, the company will optimize the design and manufacture of a full proof-of-concept assembly to evaluate its performance within Vertiia’s hydrogen fuel cell powertrain. According to Michael Fuller, CEO & Founder of Conflux Technology, ““Hydrogen fuel cells represent a transformative technology in Australia’s pursuit of sustainable energy solutions. We are proud to incorporate our heat exchange technology to enhance the efficiency and performance of Vertiia’s hydrogen fuel cells. Together, we’re advancing innovation in creating world-leading sustainable air transport.”

The Conflux cooling solution will be optimized to provide cooling for high transient heat loads experienced during vertical take-off, landing, and hover operations. Weight, performance and packaging size are key constraints for aeronautical hydrogen powertrains. Geometrical freedoms granted by additive manufacturing means heat exchangers for these systems can be lightweight and conform to the space available. Conflux’s unique thin-walled, patented designs deliver thermal performance and low drag.

AMSL Aero chairman Chris Smallhorn said: “In Vertiia we are building a hydrogen-electric aircraft that flies record-breaking distances at Formula 1 speeds, making Conflux Technology, with its storied history of innovation in motorsport and aviation, the perfect partner for us. Conflux’s AS9100D manufacturing and quality certification is critical in enabling Vertiia to become the world’s first long-range passenger-capable hydrogen VTOL.”

Working together, the companies are pioneering a future where clean energy and cutting-edge engineering drive the aviation industry toward a greener and more sustainable future. This engagement further expands Conflux’s presence in aerospace applications, leveraging additive manufacturing to develop high-performance heat exchangers for next-generation aviation. Applications now extend across propulsion system cooling, transmission and gearbox cooling, environmental and avionics cooling, and power electronics cooling. As the demand for sustainable solutions accelerates, additive manufacturing is setting new performance benchmarks, delivering advanced thermal management solutions that conventional methods cannot achieve.

Watch: News video of the Vertiia

For more information: 

Conflux Technology

AMSL Aero