Case Study: AMSL Aero achieves lightweight cooling for hydrogen VTOL aircraft with EOS GmbH and Conflux 3D printing

AMSL Aero develops 1,000-kilometer hydrogen VTOL cooling with EOS

The customer, AMSL Aero, faced the challenge of designing a high-performance, compact cooling system for its Vertiia hydrogen-electric VTOL aircraft. Traditional cooling systems were too bulky and heavy, and a new solution was needed to manage significant heat loads while integrating into the aircraft's tightly constrained geometry. The vendor, EOS GmbH, provided its metal additive manufacturing technology and EOS Aluminum AlSi10Mg material for this project.

EOS GmbH's solution, implemented by its partner Conflux Technology, utilized laser powder bed fusion (LPBF) to 3D print an ultra-compact, thin-walled heat exchanger with fluid-optimized internal geometries. This resulted in a lightweight and highly efficient cooling system tailored for integration into the aircraft's architecture. The project successfully delivered three novel heat exchanger designs in its first phase, demonstrating the ability to manage heat during critical flight maneuvers and enabling the development of the world’s first long-range passenger-capable hydrogen VTOL.

AMSL Aero