At Nikon SLM Solutions, we’re redefining the future of thermal management with the power of additive manufacturing (AM). In collaboration with Oqton, we’ve demonstrated the power of additive manufacturing by printing a cutting-edge heat exchanger on a Nikon SLM system. This application features an innovative twisted hexagonal cell structure—a design that would be impossible to achieve using conventional manufacturing methods.

This breakthrough demonstrates how AM-driven design, intelligent software, and advanced materials can unlock new levels of efficiency, durability, and performance.

Breaking Free from Traditional Constraints

For decades, heat exchanger designs have been limited by manufacturing constraints—restricted flow paths, uniform wall thicknesses, and inefficient geometries. Our latest project challenges these limitations head-on, leveraging AM’s design freedom to incorporate a twisted hexagonal cell structure that:

• Maintains uniform hydraulic diameter throughout the flow path
• Induces controlled turbulence to enhance heat transfer efficiency
• Preserves optimal backpressure, improving overall system performance
• Enhances structural rigidity while reducing overall weight

The result? A heat exchanger that is smaller, lighter, and significantly more efficient than its conventionally manufactured counterparts.

Software-Driven Innovation with Oqton’s 3DXpert

Achieving such a highly optimized design requires advanced engineering software. That’s where Oqton’s 3DXpert platform comes in. By integrating simulation, design, and manufacturing preparation into a single workflow, it eliminates traditional design bottlenecks and accelerates iteration cycles.

With 3DXpert, engineers can:

1. Simulate Flow Dynamics – Model fluid behavior through complex geometries to fine-tune turbulence patterns
2. Analyze Thermal Performance – Predict heat transfer coefficients across varied operating conditions
3. Optimize Structural Integrity – Reduce weight while ensuring mechanical stability
4. Generate Print-Ready Models – Seamlessly transition from digital design to SLM printing

This software-hardware synergy enables the rapid creation of high-performance heat exchangers, pushing the boundaries of what’s possible in thermal management.

Material Excellence: CP1 for Peak Performance

Material selection is a critical factor in heat exchanger performance. For this project, we chose CP1, a high-performance aluminum alloy with:

• Superior thermal conductivity for enhanced heat transfer
• High corrosion resistance for long-term durability
• Exceptional fatigue properties to withstand demanding operating conditions
• Optimized printability for the SLM process, ensuring precision and reliability

The combination of next-gen AM design, intelligent software, and premium materials results in a heat exchanger that outperforms traditional alternatives in every key metric.

Real-World Performance: Quantifiable Advantages

The benefits of this revolutionary approach aren’t just theoretical—testing confirms its impact:

• Up to 40% increase in heat transfer efficiency over conventional designs
• 25% reduction in overall size while maintaining equivalent performance
• 30% weight reduction through topology optimization
• Extended service life due to reduced thermal stress concentrations

These improvements translate directly into real-world advantages for industries where thermal efficiency, size, and weight are mission-critical—including aerospace, automotive, energy production, and industrial processing.

The Future of Thermal Management

As industries continue to demand higher performance, reduced weight, and improved efficiency, additive manufacturing is the key to unlocking next-generation thermal management solutions. The combination of AM technology, advanced software, and cutting-edge materials allows us to create designs that were once impossible—pushing performance to new heights.

At Nikon SLM Solutions, we’re proud to be at the forefront of this technological revolution, delivering innovations that reshape industries and redefine possibilities.

OUR MISSION, TO EMPOWER YOURS

To learn more about how Nikon SLM Solutions can help you optimize your manufacturing processes, please contact our team.