Case Studies KW Micro Power Creates Lightweight Multifunctional Microturbine Housing with Embedded Cooling Channels

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	KW Micro Power Creates Lightweight Multifunctional Microturbine Housing with Embedded Cooling Channels

KW Micro Power Creates Lightweight Multifunctional Microturbine Housing with Embedded Cooling Channels

Technology Category	Functional Applications - Product Lifecycle Management Systems (PLM) Other - Additive Manufacturing
Applicable Industries	Aerospace
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Additive Manufacturing
Services	Software Design & Engineering Services System Integration
Challenge	KW Micro Power faced the challenge of reducing the weight of their aerospace-grade Auxiliary Power Units (APUs) for commercial aviation and military applications. The primary concern was to make the APUs lightweight without compromising on performance, as every gram counts in aerospace applications. Additionally, they needed to improve the thermal management of their high power density generator to ensure optimal performance and safety. The original CNC machined housing was heavy and did not offer integrated cooling solutions, which posed a significant challenge in achieving their goals. Read More
About Customer	KW Micro Power is a small Florida-based manufacturer specializing in high power density Auxiliary Power Units (APUs) for commercial aviation and military applications. The company is known for its innovative approach to designing and manufacturing micro generator products optimized for various use cases. For landbound applications, weight is not a significant concern, but for APUs on board aircraft or drones, lightweighting is a top priority. KW Micro Power aims to stay at the forefront of the industry by adopting cutting-edge solutions and advanced engineering design tools. Read More
Solution	KW Micro Power leveraged nTopology's advanced engineering design tools to redesign the housing of their compact turbogenerator for metal Additive Manufacturing. The team used variable shelling to remove unnecessary material, creating a hollow shell with variable wall thickness. This process reduced the generator housing weight by 44%, from approximately 10.4 kg to 5.9 kg. Additionally, the hollow structure was converted into a conformal cooling channel to improve thermal management. The cooling channels used fuel as the heat transfer medium, preheating it from room temperature to 55°C, which increased the efficiency of the combustion process. The entire redesign process was performed almost instantaneously without errors and took less than a day before the part was ready for manufacturing. Read More Log in to view content
Contents

Technology Category

Functional Applications - Product Lifecycle Management Systems (PLM)

Other - Additive Manufacturing

Applicable Industries

Aerospace

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Additive Manufacturing

Services

Software Design & Engineering Services

System Integration

Challenge

KW Micro Power faced the challenge of reducing the weight of their aerospace-grade Auxiliary Power Units (APUs) for commercial aviation and military applications. The primary concern was to make the APUs lightweight without compromising on performance, as every gram counts in aerospace applications. Additionally, they needed to improve the thermal management of their high power density generator to ensure optimal performance and safety. The original CNC machined housing was heavy and did not offer integrated cooling solutions, which posed a significant challenge in achieving their goals.

About Customer

KW Micro Power is a small Florida-based manufacturer specializing in high power density Auxiliary Power Units (APUs) for commercial aviation and military applications. The company is known for its innovative approach to designing and manufacturing micro generator products optimized for various use cases. For landbound applications, weight is not a significant concern, but for APUs on board aircraft or drones, lightweighting is a top priority. KW Micro Power aims to stay at the forefront of the industry by adopting cutting-edge solutions and advanced engineering design tools.

Solution

KW Micro Power leveraged nTopology's advanced engineering design tools to redesign the housing of their compact turbogenerator for metal Additive Manufacturing. The team used variable shelling to remove unnecessary material, creating a hollow shell with variable wall thickness. This process reduced the generator housing weight by 44%, from approximately 10.4 kg to 5.9 kg. Additionally, the hollow structure was converted into a conformal cooling channel to improve thermal management. The cooling channels used fuel as the heat transfer medium, preheating it from room temperature to 55°C, which increased the efficiency of the combustion process. The entire redesign process was performed almost instantaneously without errors and took less than a day before the part was ready for manufacturing.

Impact #1	The redesigned generator housing resulted in a 44% weight reduction, making it significantly lighter and more efficient for aerospace applications.
Impact #2	The integration of conformal cooling channels led to a 33% drop in maximum operating temperatures, enhancing the thermal management of the generator.
Impact #3	The external temperature of the generator dropped by 86%, making it safe to the touch and improving overall safety.

Impact #1

The redesigned generator housing resulted in a 44% weight reduction, making it significantly lighter and more efficient for aerospace applications.

Impact #2

The integration of conformal cooling channels led to a 33% drop in maximum operating temperatures, enhancing the thermal management of the generator.

Impact #3

The external temperature of the generator dropped by 86%, making it safe to the touch and improving overall safety.

Benefit #1	Weight reduction of the generator housing by 44%, from approximately 10.4 kg to 5.9 kg.
Benefit #2	33% drop in maximum operating temperatures.
Benefit #3	86% reduction in external temperature, down to 27°C.

Benefit #1

Weight reduction of the generator housing by 44%, from approximately 10.4 kg to 5.9 kg.

Benefit #2

33% drop in maximum operating temperatures.

Benefit #3

86% reduction in external temperature, down to 27°C.

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Overview

KW Micro Power Creates Lightweight Multifunctional Microturbine Housing with Embedded Cooling Channels

Operational Impact

Quantitative Benefit