Heat exchangers are an essential part of industrial heating, cooling and fluid power systems. Optimal performance of any heat exchanger system depends on several factors:

• High efficiency heat transfer between media
• Compact size
• Ease of manufacture
• High reliability
• Low cost

Traditional manufacturing techniques rely on precision casting, advanced machining or brazed fin/tube assemblies to create units with sufficient surface area for efficient heat transfer in a compact package.

The emergence of 3D metal printing offers a new approach to manufacturing heat exchangers, but it also introduces new challenges. Linear AMS, a Moog company, took on the challenge to develop an air/oil heat exchanger using metal additive manufacturing (metal AM) techniques. Metal AM promised parts with complex internal geometries, maximum surface area and conformations impossible to manufacture using conventional techniques. The results suggest new opportunities for high performance, cost effective designs at low cost.

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