How MAX IV Optimized Cooling Performance with 3D-Printed Copper Blocks
MAX IV Laboratory explored how 3D-printed cooling blocks could enhance thermal performance and design flexibility. This internal study compared 3D-printed and traditionally machined blocks, focusing on tolerances, cooling efficiency, and suitability for ultra-high-vacuum (UHV) environments.
Why Consider 3D Printing for Cooling Blocks?
In synchrotron systems, cooling blocks play a key role in heat management. Conventional blocks rely on drilled channels joined by tubes or sealed plugs — an approach that limits flexibility and increases risk of leaks.
By contrast, metal 3D printing allows curved internal channels to be built directly into the structure. This design freedom improves heat transfer, reduces assembly time, and minimizes leak paths.
Material Selection: Why CuCrZr?
MAX IV selected CuCrZr (Copper-Chromium-Zirconium) based on previous UHV compatibility tests. It offered the right balance of thermal and mechanical properties:
High thermal conductivity for efficient cooling.
Good mechanical strength enabling knife-edge UHV seals.
Excellent vacuum performance, outperforming pure and oxygen-free copper.
Testing the 3D-Printed Cooling Block
Cooling Block Design
The cooling block was designed with curved internal channels, taking advantage of 3D printing’s ability to create complex geometries. Threads for the connectors were machined later and not directly 3D-printed.
Technical Drawings
The technical drawings highlight the internal channel structures and overall design considerations.
Figure 2: Engineering drawings of the cooling block showing channel layout.
Ordering & Printing with MakerVerse
MakerVerse is a platform for sourcing industrial parts. It provides instant access to a vetted supply chain and a full range of manufacturing technologies. With AI-powered quoting, order management, and fulfilment, MakerVerse helps with everything from initial prototypes to full-scale production.
The part was printed using LPBF (Laser Powder Bed Fusion) and arrived within the expected lead time.
Performance & Testing Results
Dimensional Accuracy
After receiving the printed cooling block, it was measured for accuracy. The most significant deviation was 0.2 mm, which was better than expected.
✅ Nominal length: 100 mm
✅ Measured length: 100.16 mm
Figure 3: CMM measurements confirming the high dimensional accuracy of the printed part. Left (Top) and Right (Bottom).
Surface Quality & Powder Removal
- Surface roughness: Ra 8-10 µm, consistent with LPBF prints.
- Some residual powder was found in the channels, but this was acceptable, as MAX IV performs in-house cleaning for UHV components.
Cooling Performance Comparison
The cooling block was tested under modified MAX IV cooling conditions:
🔹 Water Flow:0.4 l/min
🔹 Heat Input: 200W
🔹 Temperature Monitoring: thermocouples on block and water inlets/outlets
Key Findings
✅ The 3D-printed block performed well, though the machined version had slightly better cooling efficiency due to its sharper channel corners, which improved heat transfer.
✅ The 3D-printed block with multiple channels showed the best cooling performance, as expected, due to longer flow paths and proximity to the surface.
Figure 4: Cross-section of the cooling block showing internal channels after cutting.
Future Applications & Next Steps
The study demonstrated that 3D-printed copper cooling blocks are a practical option for UHV-compatible thermal components. Future tests will include pressure-drop and particle-release measurements to validate long-term performance.
MAX IV plans to explore lattice-based cooling designs to further improve heat dissipation.
Key Takeaways
✔ 3D printing enables more complex cooling channels, which can enhance performance in specific applications.
✔ Dimensional tolerances were better than expected, making LPBF a viable option for precision parts.
✔ Additional tests like pressure drop and particle release would benefit a more complete evaluation.
In future designs, MAX IV may explore alternative cooling geometries, such as lattice structures, to improve heat dissipation.
Simple and Reliable Process
The process of ordering and receiving the 3D-printed part was straightforward and efficient.
Key highlights of the collaboration:
✅ Easy online ordering – Uploading the STL file, getting an instant quote, and placing the order was hassle-free.
✅ Precision manufacturing – The final part’s dimensional accuracy was better than expected, with minimal deviation.
✅ Reliable customer support – The feedback and assistance from the MakerVerse team were helpful throughout the process.
Nils Pistora, Mechanical Engineer at MAX IV, shared his experience:
“Just upload the STL file to MakerVerse and place an order. It could not be more simple. Dimensional tolerances were surprisingly good, exceeding expectations. The ease of use of your web page, combined with instant quoting and helpful feedback from Kaitlin Wong, made the process seamless.”
Valuable Learning Experience
The evaluation confirmed that metal 3D printing enables the creation of complex internal channels that enhance cooling without compromising accuracy. While conventional machining still excels in sharp-edge geometries, additive manufacturing provides new design possibilities for high-performance thermal systems.
Ready to test 3D-printed copper components?
