Custom Cold Plates for BESS and Power Electronics OEMs
DFM review, prototype support, leak testing, pressure testing, and series-production pricing for aluminium liquid cold plates.
A power electronics cold plate is a liquid-cooled heat exchanger mounted directly on IGBT, SiC, or PCB-mounted components. ToneCooling manufactures these cold plates using vacuum brazing, stamped-and-brazed, and FSW construction, with helium leak testing performed to ASTM E499 methodology.
ToneCooling designs and manufactures custom aluminium cold plates for power electronics OEMs — IGBT and SiC power modules, inverters, converters, PCB double-sided cooling, and BESS power conversion units. This page covers how we work with engineering teams from an early CAD concept through series production, including DFM feedback, NDA-protected review, and volume pricing aligned to your SOP timeline. For battery-module-level cooling architecture, see our ESS liquid cooling plate guide.
Who this page is for
Cooling for power conversion, not just battery modules. If your project involves any of the following, this page is the right starting point:
- PCB double-sided cooling — a cold plate positioned between two populated power PCBs, cooling both sides from one coolant loop
- IGBT / SiC power module cooling — direct-attach cold plates for inverter and converter power stages
- BESS power conversion units — DC/DC and DC/AC stages, busbar cooling inside the power electronics enclosure
- Inverters and converters — solar, industrial drive, and EV powertrain inverter stages
- Chargers and high-power control boards — DC fast chargers, OBC, onboard power electronics
BESS power conversion enclosures are typically subject to system-level fire propagation testing per UL 9540A. Our cold plates are designed to support the thermal performance these system-level qualification programs require, though UL 9540A testing itself is performed at the BESS system level, not on the cold plate component.
How we work with you
Send what you have — a complete drawing isn’t required to start. We quote from a CAD concept, heat load, coolant type, and target volume, marked as an approximate quotation subject to final drawing. See the full RFQ information checklist for everything we can use.
| Stage | What you get | Typical timing |
|---|---|---|
| 1. Budgetary quote | From CAD concept + target volume, subject to final drawing | After RFQ review |
| 2. DFM report + firm quote | Drawing-level DFM comments, firm pricing | After drawing review |
| 3. First-article sample | Prototype build + validation report | 4–6 weeks |
DFM support for multiple concepts
When a project has multiple CAD concepts under evaluation, we compare manufacturing route, cost at your annual volume, and manufacturing risk before you commit to tooling. Forming feasibility is verified by molding simulation ahead of production release — for example, confirming material thinning stays within a safe range (typically 10–14%) with no rupture risk. Full checklist: Liquid Cold Plate DFM Checklist.
Manufacturing process: which route fits your volume
| Your situation | Recommended process | Typical order quantity |
|---|---|---|
| Prototype, <500 units/yr | CNC machined | 1 unit |
| Mid-volume, complex channels | FSW aluminium | 50 units |
| High volume, constant section | Extruded aluminium | 500+ units |
| Multi-layer / fine channel | Vacuum brazed / stamped & brazed | 500+ units |
Full process comparison: Cold Plate Manufacturing Process Guide.
Validation: what’s different for power electronics
Leak testing, pressure testing, and flatness inspection follow the same validated protocols across our product line — see Cold Plate Thermal Testing & Validation for full parameters. Our helium leak detection follows the detector-probe methodology defined in ASTM E499. For power electronics applications where the cold plate sits near live PCB traces or busbars, we additionally validate:
- Electrical isolation coating test — dielectric withstand testing on units with an epoxy powder isolation coating (typical thickness 200±50 µm, UL94 V0 flame rating)
NDA and confidential projects
Many power electronics and BESS projects are confidential before a patent filing or product launch — and design-stage disclosure is often the biggest hesitation before sending a CAD file to a new supplier.
- We sign a mutual NDA before reviewing CAD, heat load data, or confidential annual volume figures
- DFM review and quoting continue under NDA — an NDA does not slow down your budgetary quote timeline
- Confidential volume ramp-up figures toward SOP are handled without disclosure outside the engineering and quoting team
From prototype to series production
The transition point between stages is a cost and lead-time decision, not a fixed rule — we walk through this as part of the DFM review once your annual volume and SOP date are confirmed.
Typical project profile
Illustrative composite, not a specific customer project.
A design-phase project with multiple CAD concepts under evaluation, monoethylene-glycol/water coolant, a dielectric isolation coating requirement, leak and burst pressure testing, and an annual volume scaling into the hundreds of thousands of units as the program reaches full production.
Why ToneCooling
Three contracting entities, matched to where you buy from.
ToneCooling manufactures from a 30,000 m² facility in Huizhou, China (ISO 9001 and IATF 16949-aligned, ~1 million cold plates/year capacity). ToneCooling Texas LLC provides US-based response and contracting support, and ToneCooling Europe OÜ provides EU-based invoicing and contracting support for European customers. This three-entity combination is not something most China-based or most Western cold plate suppliers offer together.
FAQ
Can you quote before we have a final drawing?
Yes. We provide a budgetary quote from a CAD concept, heat load, and target volume, marked as subject to final drawing.
Do you support NDA before sharing CAD files?
Yes. We sign a mutual NDA before reviewing CAD, heat load data, or confidential volume figures, typically executed, and DFM/quoting continues under that agreement.
What’s different about cooling for power electronics vs. battery modules?
Power electronics cold plates near PCBs and busbars typically require an electrical isolation coating and dielectric withstand testing, in addition to the leak and pressure testing used across our product line. See our ESS liquid cooling plate guide for battery-module-specific architecture.
Do you support high-volume series production, not just prototypes?
Yes. We support annual volumes from small prototype runs into the hundreds of thousands of units, with manufacturing route and tooling selected to match your SOP volume.
Where are your cold plates manufactured?
At our 30,000 m² facility in Huizhou, China (ISO 9001 and IATF 16949-aligned). ToneCooling Texas LLC supports US-based customers and ToneCooling Europe OÜ (EU VAT EE102993675) supports European customers.
Ready to start your DFM review?
