Custom Cold Plates: High-Performance Cooling Design

March 13, 2025

Introduction

In high performance industries such as automotive, aerospace, industrial and data centers, thermal management is crucial to system reliability and performance. Off-the-shelf cold plates don’t meet the unique cooling requirements of high-power electronics, batteries, processors and applications with unusual thermal and spatial constraints.

While standard custom cold plates provide some level of cooling performance, they often fall short. Custom cold plates offer a bespoke solution by addressing specific heat dissipation requirements, geometric constraints, coolant flow requirements and material preferences that off-the-shelf products can’t accommodate. This guide provides technical insights into the fundamental considerations for designing and optimizing custom liquid cold plates for superior thermal efficiency, mechanical compatibility and long-term operational reliability.

Understanding Custom Cold Plates

A custom cold plate is a liquid cooling plate designed for a specific application to ensure optimal thermal management and mechanical compatibility. Unlike standard cold plates which have predetermined designs, custom cold plates allow for:

Tailored geometries to fit unique components and system layouts.
Specialized internal fluid channels to enhance heat transfer.
Material customization to balance conductivity, weight and durability.
Integration with specific cooling system requirements for high performance.

Custom cold plates are used in industries where precise cooling is critical such as power electronics, laser systems and semiconductor manufacturing.

Key Considerations for Custom Cold Plates

1. Thermal Load & Performance Requirements

First step in designing a custom cold plate is to determine the heat dissipation needs of your system. Key factors include:

Heat flux:Measured in W/cm², this determines the plate’s cooling capacity.
Operating temperature range:Ensuring thermal stability under varying conditions.
Coolant flow rate & pressure drop:Affects overall cooling efficiency.

Custom designs allow for enhanced heat transfer through optimized fluid channel layouts and increased surface area contact for superior cooling.

2. Material Selection: Aluminum vs. Copper

Choosing the right material is key to getting optimal thermal conductivity and durability:

Aluminum Cold Plates: Lightweight, cost-effective, corrosion-resistant.
Copper Cold Plates: Higher thermal conductivity, ideal for extreme heat loads.

For example the H100 Copper Liquid Cooling Plate is great for high power electronics.

3. Internal Channel Design & Manufacturing Techniques

Custom cold plates can be designed using various manufacturing processes each with their own thermal performance and cost:

a. Friction Stir Welding (FSW) Cold Plates

Strong, seamless bonds with no added filler material.
Low thermal resistance.

b. Tubed Liquid Cold Plates

Uses embedded tubing to circulate coolant through the plate.
Suitable for applications requiring low-pressure drop and high durability.

c. Vacuum Brazed Cold Plates

Provides high structural integrity with complex internal cooling paths.
Ideal for aerospace and high-power electronics cooling.

4. Geometric Customization & Space Constraints

Unlike standard designs, custom cold plates can be tailored to fit tight spaces and non-uniform heat sources:

Multi-zone cooling designs to manage varying heat loads.
Precision-cut shapes to integrate seamlessly with existing hardware.

5. Coolant Type & Flow Optimization

Different coolants impact heat transfer efficiency, corrosion resistance, and maintenance needs:

Water-Glycol Mixtures:Common for industrial applications.
Dielectric Fluids:Used in sensitive electronics where electrical insulation is required.

Custom cold plates allow for optimized flow dynamics, including:

Pin-fin structures for increased surface area.
Serpentine flow paths for uniform cooling.

Tubed Cold Plates at an oblique angle — Tubed liquid cold plates for laser cooling

How to Customize a Cold Plate for Your Application

Designing a custom cold plate involves multiple considerations, from understanding the thermal load to selecting the right manufacturing process, materials, and internal structure. Each step in the customization process ensures the cooling solution is tailored for maximum efficiency and long-term reliability. Below is a detailed breakdown of how to engineer a high-performance liquid cold plate for your application.

Step 1: Define Heat Load & System Requirements

Before designing a custom cold plate, it is crucial to determine the heat dissipation requirements of your system. The following factors play a critical role:

Heat Source Power Output

The total power output of the components generating heat needs to be measured in watts (W).
High-powered electronics (e.g., IGBT modules, CPUs, and laser systems) demand efficient thermal dissipation to prevent overheating and failure.

Cooling Efficiency Requirements

The cooling system must maintain component temperatures within a specified safe operating range.
Industries such as EV battery cooling, industrial automation, and medical devices require precise temperature control to ensure optimal functionality and safety.

Operating Environment Factors

Temperature: Will the system be in extreme heat or fluctuating temperatures?
Humidity:Is there moisture or potential for condensation?
Pressure Constraints:Some systems require high pressure coolant flow which affects pump selection and cold plate design.

Knowing these parameters allows for optimized cold plate design to make sure the system performs in real world operating conditions.

Step 2: Select the Right Manufacturing Method

Different manufacturing techniques impact thermal performance, cost and durability of the custom cold plate. Choosing the right method depends on the performance requirements and budget of the application.

Friction Stir Welding (FSW) Cold Plates – Best for High-Performance Cooling

Utilizes a solid-state joining process, creating a seamless, high-strength bond between plate layers.
Advantage:No added filler material, ensuring low thermal resistance and excellent heat transfer.
Ideal for:EV battery cooling, power electronics, and high-performance computing.

Vacuum Brazed Cold Plates – Ideal for Complex Internal Channels

Allows for intricate, multi-layered internal cooling paths.
Advantage:High structural integrity and superior cooling efficiency.
Ideal for: Aerospace, semiconductor cooling, and industrial automation.

Tubed Liquid Cold Plates – Cost-Effective Alternative

Uses embedded tubing (copper or stainless steel).
Advantage:Simple, reliable, cheaper than welded or brazed plates.
Ideal for: HVAC, LED cooling, industrial power supplies.

Choosing the right manufacturing process gets the custom cold plate to performance, cost, durability spec.

Step 3: Choose the Ideal Material

Material selection plays a big role in heat transfer, weight and corrosion. The most common materials are aluminum and copper, each has its advantages:

Aluminum Cold Plates – Lightweight & Cost-Effective

Thermal Conductivity:~205 W/m·K (lower than copper but good enough for many applications).
Corrosion Resistance:Forms an oxide layer naturally, longer life.
Advantage:Up to 60% lighter than copper, good for applications where weight is a must.
Ideal for: EV cooling, aerospace, general electronics cooling.

Copper Cold Plates – Superior Thermal Performance

Thermal Conductivity: ~385 W/m·K (almost double that of aluminum).
Heat Transfer Efficiency:Best for high-power electronic cooling and extreme heat loads.
Durability:Less wear and tear but heavier than aluminum.
Ideal for:High performance computing, semiconductor cooling, laser systems.

When designing a custom cold plate, the material should match thermal requirements, weight constraints and environmental exposure.

Step 4: Optimize Internal Flow Channels

The fluid flow inside the cold plate is key to maximizing heat transfer while minimizing pressure drop. Advanced CFD simulations help fine tune the channel layout for optimal cooling.

Key Internal Flow Channel Designs

Straight Flow Channels:
- Best for low-resistance coolant flow with minimal pressure drop.
- Commonly used in HVAC and industrial power applications.
Serpentine Flow Paths:
- Enhances heat absorption by increasing fluid contact time.
- Used in high-performance electronics cooling.
Pin-Fin Structures:
- Maximizes surface area for improved heat dissipation.
- Preferred in semiconductor cooling and power inverters.

Custom flow paths allow engineers to balance cooling efficiency, pressure drop and manufacturing complexity for specific applications.

Step 5: Ensure Long-Term Reliability & Cost-Effectiveness

A well designed custom cold plate should not only perform better but also be reliable in the long term with minimal maintenance. Several strategies can improve durability and cost effectiveness:

1. Implement Anti-Corrosion Coatings

Anodizing (for aluminum):Protects against oxidation and corrosion.
Nickel Plating (for copper):Prevents degradation in humid environments.
Best for:Applications in marine, aerospace, and outdoor industrial settings.

2. Use Predictive Thermal Modeling for Performance Validation

CFD simulations can predict hot spots, flow uniformity and pressure drops before manufacture.
Avoid costly design mistakes and optimize cooling upfront.

3. Optimize for Manufacturing Feasibility

Over complex designs will increase cost and reduce manufacturability.
Picking the right balance between performance, complexity and budget will get you the best result.

By incorporating protective coatings, thermal modeling and cost conscious design decisions custom cold plates can deliver consistent performance over their operational life.

Conclusion

Custom cold plates offer unparalleled thermal efficiency, design flexibility and performance optimisation. By considering heat load, material selection, internal channel design and manufacturing methods companies can achieve cooling solutions tailored to their exact needs.

TONE Cooling specialise in custom liquid cold plates for maximum efficiency and durability