The “Advanced Heat Exchange Devices”(AHEAD), focuses on the development of 3D-printed pipe segments with integrated heating and sensing functions, designed for in situ measurements and energy harvesting in demanding environments such as space and industrial thermal management systems.
This R&D&I project emerged as a natural progression after the success of SWAP, an initiative developed during ATTRACT phase 1, which demonstrated 3D-printed pipe segments with embedded hydraulic fittings and Aerosol Jet-printed Resistance Temperature Detector‐ for fluid contact. Following SWAP’s conclusion, the Swiss Center for Electronics and Microtechnology (CSEM) further advanced the technology, enhancing printing quality to eliminate the need for mechanical post-processing and consolidating the full closure of the instrumented section by resuming the 3D printing process after depositing the sensor using Aerosol Jet technology.
In that sense, AHEAD aims to enhance these technologies by expanding capabilities with Commercial-Of-The-Shelf sensor integration, 3D printing of heating elements, standalone operation thanks to energy harvesting and finally, manufacturing process optimization. This evolution will enable the development of advanced, self-monitoring pipe systems for broader industrial and scientific applications, ultimately bringing these innovations to a Technology Readiness Level 7 (TRL7) through two specific use cases: Mechanically Pumped Loops (MPL) targeting thermal management applications for satellite platforms and CO2-based industrial refrigeration systems.
“The technological building blocks developed in this project are designed to be versatile and applicable to various other applications. I’m particularly excited to see that this cross-fertilization process is already in motion, with several unexpected applications currently being discussed or already under development,
explained Hervé Saudan, coordinator of AHEAD and Group Leader of Precision Mechanisms at CSEM.
Progress and key milestones achieved
Through the last months, the research team have been working on finalizing the development with the execution of system-level tests that enabled TRL7 to be achieved. Furthermore, the AHEAD consortium organized a webinar to present the development status of the technological building blocks and the two applications addressed by the project: Thales Alenia Space satellite thermal management systems and CERN’s new particle detector cooling systems.
On the other hand, the research team has remained highly active, participating in conferences to showcase progress and to gather valuable insights that help them deepen the technological needs specific to different sectors of activity. In 2024, they attended Space Tech in Bremen, Germany where they had the opportunity to present the prototypes. Additionally, Saudan shared key updates at the World Advanced Manufacturing Symposium in Orlando, USA.
They also took part in the European Conference on Spacecraft Structures, Materials, and Environmental Testing (ECSSMET) 2024 in the Netherlands. During this conference, they discussed the results and lessons learned from the design, manufacturing and testing of the prototypes they had developed. In addition, the research team will present the results of AHEAD at the BRIDGE-AM Symposium in Bordeaux, whose purpose is to form European consortia to develop metal additive manufacturing.
AHEAD main applications
One of AHEAD’s applications focuses on CO₂ refrigeration systems, an emerging technology in the refrigeration industry. The second application targets thermal management systems for satellite platforms. The advanced pipe segments developed through this project aim to enhance system efficiency, contributing to significant energy savings.
Moreover, the developed technology bricks make it possible to integrate electrical components —such as cables, connectors, sensors and heaters— into different types of 3D-printed structures, enhancing their functionality and versatility across multiple applications.
AHEAD is coordinated by CSEM in partnership with five organizations: CERN, inanoEnergy, LISI Aerospace Additive Manufacturing, Norwegian University of Science & Technology, and Thales Alenia Space France.
Here you can watch a video of the AHEAD project:
For additional information about the project, visit here.
The “Advanced Heat Exchange Devices”(AHEAD), focuses on the development of 3D-printed pipe segments with integrated heating and sensing functions, designed for in situ measurements and energy harvesting in demanding environments such as space and industrial thermal management systems. This R&D&I project emerged as a natural progression after the success of SWAP, an initiative developed during […]
