Case Study: Fast Radius achieves 2X improved heat transfer in 3D-printed heat exchangers with Carbon DLS

Fast Radius Demonstrates 2X Improved Heat Transfer in 3D Printed Heat Exchangers

Fast Radius faced the challenge of improving heat exchanger performance beyond the limits of traditional manufacturing, which constrains internal geometries and raises assembly costs. Working with Carbon and its Digital Light Synthesis (Carbon DLS) process, Fast Radius explored new contoured and twisted channel designs and high–heat resistant Carbon Cyanate Ester (CE 221) material to overcome these constraints.

Using Carbon’s DLS technology, Fast Radius 3D printed integrated manifolds and mixing structures directly into flow channels, producing lighter, lower‑cost heat exchangers that transfer twice the amount of heat using smaller fluid volumes. The Carbon-enabled solution reduced assembly and labor, allowed device miniaturization, and delivered measurable energy‑efficiency and performance gains (2x heat transfer).

Fast Radius

Bill King

Chief Science Officer