Articles tagged with "thermal-management"
China's new cooling system can touch sub-zero in seconds to save AI
Chinese researchers have developed a novel pressure-driven chemical cooling technique that can rapidly supercool a liquid medium to sub-zero temperatures within 30 seconds. Unlike traditional cooling methods that rely on continuous energy input such as fans or chilled water loops, this process uses the unusual solubility behavior of ammonium thiocyanate salt under pressure. When pressurized, a saturated salt solution forms, and upon sudden pressure release, the salt re-dissolves in a way that absorbs significant heat from the surroundings, causing a rapid temperature drop. This endothermic dissolution, enhanced by pressure control, offers a high cooling power burst ideal for managing sudden thermal spikes. This technology shows promise for energy-intensive AI data centers, which generate intense heat from GPUs and other hardware, often facing unpredictable heat surges during computationally demanding tasks. The rapid salt cooling process could act as a thermal buffer, reducing peak cooling loads and potentially lowering energy costs associated with traditional cooling systems that can consume 30-50% of a data center
energycooling-technologydata-centersAI-hardwarechemical-coolingthermal-managementammonium-thiocyanateOne-way heat diode could help batteries run cooler and last longer
University of Houston engineers have developed a novel thermal rectification technique that enables heat to flow in only one direction, akin to an electrical diode but for heat. This breakthrough allows unprecedented control over device temperatures by permitting forward heat transfer while completely blocking reverse flow. Achieved through semiconductor materials subjected to a magnetic field, this innovation precisely controls radiative heat at the microscopic level, addressing the longstanding challenge of managing heat that traditionally spreads in all directions and causes overheating in electronics. The technology promises to extend battery life in cell phones, electric vehicles, satellites, and improve efficiency in AI data centers by maintaining optimal operating temperatures even under extreme conditions. Beyond unidirectional heat flow, the research team is also developing a thermal circulator device that moves radiative heat in a continuous loop among multiple surfaces, further enhancing thermal management capabilities. Additionally, a companion study demonstrates that asymmetric thermal conductivity can enable conduction heat rectification, bridging theoretical concepts with practical applications for microchips and high-performance batteries. This technology holds particular promise for space
energythermal-managementbattery-technologysemiconductor-materialsheat-dioderadiative-heat-flowelectronics-coolingJapanese team makes palm-sized microreactor to power robots, drones
Japanese researchers at the Institute of Science, Tokyo, have developed a palm-sized Solid Oxide Fuel Cell (SOFC) microreactor designed to power high-demand edge devices such as drones, robotics, and AI hardware. Unlike conventional industrial SOFCs that require about 30 minutes to reach operating temperatures of 600°C, this microreactor heats up within five minutes from a cold start. The key innovation lies in its “scaffolding” design using yttria-stabilized zirconia (YSZ), a specialized ceramic formed into a flexible, cantilevered structure that minimizes thermal conduction and stress, preventing cracks that typically plague small-scale SOFCs due to intense heat. The microreactor integrates microchannels for fuel and water flow within a lightweight, multilayered insulation system that traps heat effectively, isolating the high internal temperatures from the external environment. This design not only ensures structural integrity but also enables rapid heating and efficient energy conversion, offering up to four times the energy density of
energysolid-oxide-fuel-cellmicroreactorportable-powerroboticsdronesthermal-managementUS fusion facility to test powerful materials under extreme heat flux
The Tennessee Valley Authority’s Bull Run Energy Complex in Tennessee is preparing to host a new high-heat flux (HHF) testing facility, a collaborative project involving the Department of Energy’s Oak Ridge National Laboratory (ORNL), Type One Energy, and the University of Tennessee, Knoxville (UT). Scheduled for completion by the end of 2027, the facility will simulate the extreme heat flux conditions found in fusion reactors—targeting steady-state heat loads exceeding 10 megawatts per square meter—to test plasma-facing components (PFCs) that must endure intense operational stresses. This will be the second such facility in the U.S. and the most powerful, uniquely featuring pressurized helium gas cooling, which is favored in several domestic fusion reactor designs due to helium’s chemical stability under fusion conditions. The Bull Run site, already home to Type One Energy’s Infinity One stellarator testbed, is envisioned as a fusion development campus integrating research from ORNL, UT, and industry partners. ORNL
energyfusion-energyhigh-heat-flux-testingmaterials-sciencefusion-reactorsthermal-managementenergy-research3x more efficient: Metallic material with highest thermal conductivity identified
Researchers at UCLA Samueli School of Engineering have identified theta-phase tantalum nitride (θ-TaN) as a metallic material with the highest thermal conductivity measured among metals, conducting heat nearly three times more efficiently than copper or silver. This discovery challenges previous assumptions about the limits of heat transport in metals, where copper has long been the standard with a thermal conductivity of about 400 W/m·K. The team experimentally realized single-crystalline θ-TaN, measuring a room-temperature thermal conductivity of approximately 1100 W/m·K. This exceptional performance is attributed to the material’s unique atomic structure—tantalum and nitrogen atoms arranged in a hexagonal pattern—which leads to a distinctive phonon band structure that suppresses phonon-phonon scattering and exhibits weak electron-phonon coupling. The findings, published in the journal Science, have significant implications for thermal management in electronics, particularly as AI technologies and high-performance computing systems increasingly demand efficient heat dissipation to prevent overheating and maintain reliability. Currently
materialsthermal-conductivitytantalum-nitrideheat-dissipationelectronic-devicesthermal-managementmetals2,500-year-old board game inspires AI to tackle engine, data center overheating
A team of scientists led by Associate Professor Jiangtao Cheng at Virginia Tech has developed an AI-driven approach to optimize spray cooling, inspired by the ancient Chinese board game Go and Google’s AlphaGo AI. Recognizing parallels between Go’s interconnected strategic dynamics and the complex parameters of spray cooling systems, the researchers applied machine learning to analyze and predict the most effective cooling strategies. Their goal is to improve thermal management for electrical grids, data centers, engines, computers, and turbines, helping these systems operate efficiently amid rising demand and prevent overheating. The research, published in the journal Artificial Intelligence Review, focuses on the role of water droplets in spray cooling, where rapid evaporation of droplets carries away heat from hot surfaces. The team used AI to analyze data from 25 prior studies, evaluating factors such as optimal droplet size, spray nozzle types, and potential alternatives to water like solvents or engineered mixtures. This machine learning approach allowed them to better understand the thermo-fluid dynamics involved and to propose more effective cooling designs.
energyAI-coolingdata-center-coolingspray-coolingmachine-learningthermal-managementheat-dissipationWorld-1st laptop cooled by dielectric barrier discharge to debut at CES 2026
YPlasma, a New Jersey-based company, is set to debut the world’s first laptop cooled using Dielectric Barrier Discharge (DBD) plasma actuators at CES 2026. This innovative cooling solution replaces traditional mechanical fans and ionic wind devices by generating high-velocity “ionic wind” through cold plasma without any moving parts. The miniaturized DBD technology, presented as ultra-thin films as slim as 200 microns, can be integrated directly onto heat sinks or internal components, enabling ultra-thin laptop designs that were previously unfeasible to cool. Additionally, these actuators uniquely provide both cooling and heating functions within the same device, offering enhanced thermal versatility. YPlasma emphasizes that their DBD plasma cooling system operates nearly noiselessly at 17 dBA, eliminating typical fan noise in high-performance laptops. Unlike corona discharge methods, YPlasma’s dielectric barrier limits harmful ozone production and prevents “tip erosion,” significantly improving safety, reliability, and device longevity.
materialscooling-technologydielectric-barrier-dischargeplasma-actuatorsconsumer-electronicsthermal-managementlaptop-innovationRethinking deicing as an electrostatic problem
The article "Rethinking deicing as an electrostatic problem" discusses a novel approach to frost removal developed by engineers at Virginia Tech, which leverages the electrostatic properties of frost rather than relying on traditional thermal or mechanical methods. Conventional deicing techniques—such as heaters, reverse-cycle defrosting, glycol sprays, and mechanical scrapers—are energy-intensive, environmentally problematic, or add complexity and maintenance challenges. In contrast, the new method, called electrostatic defrosting (EDF), exploits the fact that frost naturally develops a small internal voltage when exposed to a temperature gradient, making it behave like a charged, polarizable dielectric. By applying an external electric field via a charged electrode plate, the frost can be effectively pulled off surfaces without melting, reducing energy consumption and hardware requirements. This shift in perspective reframes deicing as an electrostatic challenge rather than a purely thermal one, opening new avenues for research into charge transport, fracture mechanics, and scalability of the technique. The article highlights
energyelectrostatic-defrostingdeicing-technologyfrost-removalenergy-efficiencyelectric-fieldsthermal-managementVideo: Victorian-era radiator turned into cooling system for gaming PC
Billet Labs, a London-based PC cooling specialist, has repurposed a century-old cast-iron Victorian-era radiator into the central cooling system for a modern gaming PC. Weighing around 110 pounds (50 kilograms) and holding over 10 liters of liquid, the radiator serves as a massive passive cooling vessel. The PC components are mounted beneath the radiator rather than inside a conventional case, with copper heatsinks and extensive pipework connecting heat-producing parts to the radiator’s large thermal mass. This design merges industrial-age hardware with contemporary computing, resulting in a visually striking steampunk aesthetic featuring ornamental feet and rounded iron fins. This build aligns with Billet Labs’ history of unconventional, visually distinctive cooling solutions, often incorporating solid copper and exposed plumbing. While specific hardware details remain undisclosed, the system is intended to cool high-performance CPUs and GPUs, which typically generate significant heat and are challenging to cool quietly. Although the passive cooling approach offers substantial heat dissipation potential due to the radiator’s size
energycooling-systemPC-hardwarethermal-managementpassive-coolingcopper-heatsinkscast-iron-radiatorWorld's first 800V immersion-cooled battery targets AI power demand
XING Mobility is unveiling the world’s first 800V immersion-cooled high-voltage DC backup battery system, called BBx800, designed specifically for AI data centers at CES 2026. This system leverages full immersion cooling by submerging each battery cell in an insulating fluid to maintain stable operating temperatures between 25°C and 27°C, reducing thermal runaway risk and enhancing stability under extreme loads. The compact module supports voltage configurations of ±400V or 800V, and a standard 20 OU rack can deliver peak outputs up to 1 MW for three minutes or 1.2 MW for 90 seconds, targeting short-duration backup during rapid power fluctuations and peak AI workloads. The development responds to the rising power demands of AI data centers, where per-rack power consumption has surged from around 100 kW to over 1 MW, challenging traditional 48V architectures due to current, thermal, and efficiency constraints. NVIDIA’s 2025 push for 800V
energybattery-technologyimmersion-coolingAI-data-centershigh-voltage-systemsenergy-storagethermal-managementPhotos: Ford’s tiny nuclear reactor-powered car concept that never hit the road
In 1958, Ford unveiled the Ford Nucleon, a visionary concept car powered by a compact nuclear reactor instead of gasoline. Developed by Ford’s Advanced Styling Studio under industrial designer George W. Walker, the Nucleon was designed to explore future mobility technologies and spark discussion about atomic propulsion. The vehicle featured a rear-mounted nuclear reactor housed in a "Power Capsule," with a cab-forward, bubble-style cockpit inspired by fighter jets to maximize passenger distance from the reactor. Cooling was managed through air intakes on the roof to address the significant heat generated by the reactor, and the propulsion system was based on a closed-loop steam turbine powered by Uranium 235, aiming for long driving ranges without conventional refueling. Ford envisioned a replaceable reactor capsule system, where drivers would swap out depleted capsules at specialized stations every 5,000 miles, addressing safety and convenience concerns. However, the Nucleon never progressed beyond the design stage due to insurmountable engineering challenges. The most critical
energynuclear-powerautomotive-technologyconcept-carthermal-managementsteam-turbinealuminum-materialsCooling tech transforms EV performance with ultra-fast charging
The article discusses Hydrohertz, a British startup that has developed the Dectravalve, an advanced multi-zone battery cooling technology aimed at significantly improving electric vehicle (EV) performance. Unlike traditional cooling systems that treat the entire battery pack uniformly, the Dectravalve provides precise thermal management by independently heating or cooling individual battery modules. This approach maintains consistent temperatures across all cells, maximizing efficiency, reliability, and safety, which enables ultra-fast charging, extended battery range, and longer battery lifespan. The Dectravalve system consolidates thermal flow control into a single intelligent unit capable of managing up to four distinct outlets simultaneously, eliminating the need for multiple valves and complex piping. Its modular design allows easy integration into various applications, including EVs, data centers, and aviation. In tests with a 100 kWh Lithium Iron Phosphate (LFP) battery, the technology kept cell temperatures below 44.5°C with minimal temperature variation, compared to typical fast-charging peaks of
energyelectric-vehiclesbattery-coolingthermal-managementultra-fast-charginglithium-iron-phosphateenergy-efficiencyHow a startup is reinventing cryogenic rocket hardware
Astrophel Aerospace, a startup focused on reusable cryogenic rocket engines, is innovating turbopump technology to overcome one of rocketry’s toughest challenges: surviving extreme thermal gradients and mechanical stresses. Turbopumps must operate with one end exposed to turbine gases near 980°C and the other to cryogenic fuels below –180°C, spinning at 25,000 RPM. This creates severe material and design challenges, as thermal expansion mismatches can warp shafts, degrade seals, and seize bearings, often destroying engines and preventing reuse. Astrophel’s gas-generator-cycle turbopump, currently undergoing tests at ISRO facilities, aims to withstand 60–70 thermal cycles while eliminating battery packs, reducing mass, and delivering liquid oxygen at 4.1 kg/s with a pressure ratio of about 10. Unlike electric pump-fed engines that rely on heavy battery packs, Astrophel’s design uses a gas generator to burn a small fraction of propellant, driving the turbine and powering the
materialsaerospace-engineeringcryogenic-technologyturbopumpreusable-rocketsthermal-managementpropulsion-systemsNew ‘All-Climate Battery’ could keep EVs running in extreme heat, cold
Researchers at Penn State have developed a novel lithium-ion battery design called the All-Climate Battery (ACB) to overcome the limitations of standard lithium-ion batteries in extreme temperatures. Traditional lithium-ion batteries are optimized for around 25°C and suffer from power loss in cold conditions and instability in hot environments, which poses challenges for applications like electric vehicles, data centers, and other large-scale systems. The current workaround involves bulky, energy-intensive external heating and cooling systems that only allow operation between -30°C and 45°C. The ACB employs a dual-strategy approach to address these issues. First, it replaces the volatile liquid electrolyte with more stable materials to enhance safety and performance at high temperatures. Second, it integrates an internal heating element—a thin nickel foil film powered by the battery itself—to maintain optimal temperatures in cold conditions without compromising material stability. This built-in thermal management reduces space, power consumption, and maintenance, offering significant cost savings for large battery-dependent facilities. The resulting battery is expected to operate
energylithium-ion-batteryelectric-vehiclesbattery-technologythermal-managementextreme-temperatureenergy-storageThis startup’s metal stacks could help solve AI’s massive heat problem
The article discusses Alloy Enterprises, a startup addressing the escalating cooling challenges posed by increasingly power-hungry AI data center racks. Nvidia recently revealed that future GPU racks, expected in 2027, could consume up to 600 kilowatts of electricity—nearly double the capacity of some fast EV chargers. This surge in power density creates significant heat dissipation issues, especially for peripheral chips like memory and networking hardware, which account for about 20% of a server’s cooling load but currently lack effective cooling solutions. Alloy Enterprises has developed a novel cooling technology using stacks of copper sheets bonded through a process called diffusion bonding or "stack forging," producing seamless, solid metal cold plates that can fit into tight spaces and withstand high liquid cooling pressures. Unlike conventional machined cold plates, which are assembled from separate halves and prone to leaks at seams, Alloy’s stack forging method creates single-block copper plates with no seams and superior structural integrity. This process also allows for finer features—down to 50 mic
energymaterialscooling-technologyadditive-manufacturingmetal-bondingdata-centersthermal-managementMIT study could unlock next-gen cooling for nuclear cores, spacecraft
MIT doctoral candidate Marco Graffiedi is researching advanced cooling techniques that could revolutionize thermal management in next-generation nuclear reactors and spacecraft. His work focuses on enhancing the quenching process—a highly efficient heat transfer method—by accelerating the collapse of the insulating vapor film known as the Leidenfrost effect during cryogenic cooling. This advancement aims to enable faster and more efficient in-orbit refueling, addressing a critical challenge faced by NASA and SpaceX, particularly in preventing cryogenic fuel boiloff that leads to fuel loss and tank overpressurization during space missions. Beyond space applications, Graffiedi’s research also explores immersion cooling for data centers using dielectric fluids, which currently have lower critical heat flux (CHF) than water. He demonstrated that applying high electric fields can increase CHF and enable gravity-independent boiling, which is crucial for cooling in electric vehicles and high-performance computing environments. Efficient cooling solutions are increasingly important due to rising energy demands driven by AI and data processing, with some proposing orbital data
energynuclear-reactorsspacecraft-coolingcryogenic-fuelthermal-managementin-orbit-refuelingdata-center-coolingSolaris Shows Off New Midibus at Busworld 2025 - CleanTechnica
At Busworld 2025 in Brussels, Polish manufacturer Solaris Bus & Coach unveiled the Solaris Urbino 10.5 electric midibus, a 10.5-meter fully electric city bus designed for high maneuverability and optimized passenger capacity in tight urban environments. The Urbino 10.5 electric features a modular drive system standardizing components across the Urbino family, simplifying maintenance and reducing complexity for fleet operators. On its debut day, it won the Sustainable Bus Award 2026 in the “Urban” category, highlighting its innovation and sustainability credentials. Solaris also showcased its zero-emission portfolio, including the award-winning Solaris Urbino 18 hydrogen fuel-cell bus, named International Bus of the Year 2025—the first hydrogen vehicle to earn this distinction—and the Urbino 12 electric, which won the Sustainable Bus Award 2025. Solaris emphasized its commitment to zero-emission public transport and its international growth strategy, particularly expanding in North America with recent major contracts in the U.S.
energyelectric-vehicleszero-emissionhydrogen-fuel-cellpublic-transportbattery-technologythermal-managementHiger Electric V Series Coaches Updates Fleets in Busworld 2025 - CleanTechnica
At Busworld 2025 in Brussels, Chinese manufacturer Higer unveiled its new electric V Series coaches tailored for the European market, marking a significant step in its focus on EV buses. The lineup, developed over three years using Integrated Product Development and European market research, includes three models: the V12E Pro luxury coach, the V12E tourist coach, and the V13E intercity coach. The flagship V12E Pro is a 12.4-meter luxury coach designed for long-distance travel, featuring a 399.91 kWh battery with a 500 km range, advanced thermal management, nitrogen protection, and a 15-year or 1.5 million-kilometer warranty. It offers amenities like wheelchair accessibility, premium interiors, and a luggage compartment exceeding 10 cubic meters, claimed to be a first for a 12-meter electric coach. The V Series is built on a modular platform scalable from 8 to 14 meters and compatible with electric, diesel, and hydrogen
energyelectric-vehiclesbattery-technologymodular-platformremote-diagnosisthermal-managementhydrogen-powertrainsAirbus backs 3D-printed heat exchanger to cool hydrogen-electric jets
Airbus is advancing its hydrogen-electric aviation efforts through collaboration with Conflux Technology, which is developing a next-generation 3D-printed heat exchanger critical for thermal management in megawatt-class hydrogen fuel cell systems. This lightweight, high-performance component, created using additive manufacturing and validated with Computational Fluid Dynamics (CFD) modeling, is designed to regulate the substantial heat generated by hydrogen fuel cells, ensuring safe and efficient operation of Airbus’ ZEROe hydrogen-electric propulsion systems. The ZEROe program aims to produce the first zero-emission commercial aircraft powered by hydrogen fuel cells, targeting entry into service by 2035, with water vapor as the only emission. Despite technological progress, including successful testing of a 1.2-megawatt fuel cell engine and advancements in liquid hydrogen storage, the ZEROe program has faced delays, pushing the timeline back by 5 to 10 years and reducing its budget by 25%. These setbacks stem from the complexity of developing the propulsion technology and establishing a global
energyhydrogen-fuel-cells3D-printingaerospacethermal-managementadditive-manufacturingsustainable-aviationMicrosoft in-chip cooling breakthrough cuts GPU heat rise by 65%
Microsoft has developed a breakthrough in-chip microfluidic cooling technology that channels liquid coolant directly inside GPU chips to remove heat more efficiently. This approach carves microscopic grooves into the silicon, enabling coolant to flow in direct contact with hot spots, which reduces the maximum GPU temperature rise by up to 65% and outperforms traditional cold plate cooling systems by as much as three times. The system also leverages AI to identify heat patterns and direct cooling precisely where needed. Microsoft successfully demonstrated this technology by cooling a server running simulated Teams meetings and is now prioritizing reliability testing. The design was inspired by natural vein structures, with Microsoft collaborating with Swiss startup Corintis to create bio-inspired coolant channels that improve heat dissipation compared to straight channels. The engineering challenge involved balancing channel depth for effective coolant flow without compromising silicon strength, developing leak-proof chip packaging, and integrating etching processes into chip manufacturing. Beyond individual chips, Microsoft envisions microfluidics playing a major role in datacenters by enabling more
energycooling-technologymicrofluidicsGPU-coolingAI-hardwaresemiconductor-materialsthermal-managementGerman firm's extender system boosts EV range to as much as 840 miles
German automotive supplier MAHLE, based in Stuttgart, has developed a new range extender system designed to significantly boost the driving range of battery-electric vehicles (BEVs) up to approximately 840 miles (1,350 km) on a single battery charge. The system features a highly efficient high-voltage generator powered by a small combustion engine, which nearly doubles the range of current longest-range BEVs. This innovation aims to address range anxiety by enabling smaller, more cost-effective batteries that reduce vehicle weight and charging times, while maintaining reliability and efficiency. MAHLE emphasizes that the system is ready for series production and integrates seamlessly into a holistic vehicle architecture. In addition to the range extender, MAHLE has introduced a compact thermal management module with an integrated heat pump that can increase EV range by up to 20% in low-temperature conditions by efficiently managing the vehicle’s cooling and heating needs without requiring additional heating systems. This module ensures optimal temperature control for the drive and energy storage systems, enhancing overall vehicle
energyelectric-vehiclesrange-extenderbattery-technologythermal-managementhigh-voltage-generatore-mobilityEV thermal fluid helps battery to be charged from 10-80% in ten minutes
Shell Lubricants has developed a high-performance thermal management fluid called EV-Plus Thermal Fluid, which, when used in an immersion cooling system, enabled a 34 kWh EV battery pack to charge from 10% to 80% capacity in under ten minutes during testing. This breakthrough addresses a major barrier to electric vehicle (EV) adoption—long charging times—cited by over 44% of non-EV drivers in key markets. The immersion cooling method involves submerging battery cells directly in the electrically non-conductive fluid, allowing uniform and efficient heat dissipation, which improves battery thermal performance, safety, and longevity under high-speed charging conditions. Shell projects that, applied to future aerodynamic EVs with high efficiency (around 10 km/kWh), this technology could add approximately 24 kilometers (14 miles) of range per minute of charging, significantly surpassing current market standards like the Lucid Air Pure. The fluid is formulated using Shell’s proprietary Gas-to-Liquid (
energyelectric-vehiclesbattery-technologythermal-managementimmersion-coolingfast-chargingShell-LubricantsChina: BYD's electric hypercar hits 293 mph to set new world record
China’s BYD sub-brand Yangwang has set a new world record for electric vehicles (EVs) with its U9 Track Edition hypercar, reaching a top speed of 293.54 mph on August 8 in Germany. This 3,000-horsepower quad-motor car surpasses the previous EV speed record of 272.6 mph held by Japan’s Aspark Owl in 2024, demonstrating that electric hypercars can now outperform many traditional combustion-engine rivals. The U9 Track Edition builds on the standard U9 platform but features significant upgrades, including a pioneering 1,200-volt ultra-high-voltage system and advanced thermal management, enabling it to sustain immense power without overheating. The vehicle’s four electric motors each produce 744.26 horsepower and can spin up to 30,000 rpm, collectively delivering nearly 3,000 horsepower. It incorporates Yangwang’s DiSus-X Intelligent Body Control System for exceptional handling, allowing maneuvers like driving on three
energyelectric-vehicleselectric-hypercarhigh-voltage-platformthermal-managementtorque-vectoringcarbon-fiber-materialsMercedes-AMG EV sets 25 records with Earth-circling endurance feat
Mercedes-AMG’s Concept AMG GT XX prototype has set 25 endurance records by completing a 24,901-mile run in just seven and a half days at Italy’s Nardò test track—equivalent to circling the Earth’s equator. The two prototypes averaged 137 mph over 3,177 laps on the 7.87-mile circuit, demonstrating that electric vehicles can sustain high speeds for extended periods without failure. This achievement addresses long-standing skepticism about EV endurance and performance, breaking records across distances from 1,243 miles up to the full 24,901 miles. Key to this feat was the car’s advanced powertrain, featuring three compact axial-flux motors producing a combined 1,341 horsepower, paired with a direct-cooled battery system derived from Formula 1 technology to manage thermal challenges under extreme conditions. The GT XX also showcased ultra-fast charging capabilities, adding up to 249 miles of range in just five minutes via 850 kW charging hardware, enabling
electric-vehiclesMercedes-AMGaxial-flux-motorsbattery-coolingfast-chargingEV-endurancethermal-managementWater-cooled computer looks like a Victorian machine on the wall
The article highlights a unique steampunk-inspired, water-cooled computer built by modder Felix Ure of Billet Labs, known for combining Victorian-era aesthetics with high-performance PC hardware. This wall-mounted PC resembles a vintage time machine, featuring brass and copper plumbing that serves both as an artistic element and an efficient custom water-cooling loop. The open-air design showcases every component, with analog dials and industrial-grade fans enhancing the retro, industrial character. The build started from a metal-backed panel to support heavy components and elaborate cooling, with meticulous placement ensuring a balanced and symmetrical appearance. Inside, the system boasts top-tier hardware including an AMD Ryzen 9 9950X CPU, NVIDIA GeForce RTX 3090 Ti GPU, 64GB RAM, 8TB storage, and a B650 EI motherboard, making it capable of demanding tasks like 4K video editing and 3D scanning. The cooling system features hand-soldered copper pipes and a reservoir, supported by four high
materialscooling-technologywater-coolingcomputer-hardwarecustom-PC-buildsteampunk-designthermal-managementOld Ideas Lead To New Thinking About Comfort In Homes & Buildings - CleanTechnica
The article from CleanTechnica highlights how traditional, passive cooling techniques are being rediscovered and adapted to improve comfort in homes and buildings amid rising summer temperatures. It draws on historical practices, such as those used in Spain and Persia, where thick stone walls, awnings, and qanat systems—ancient underground water channels that cool air flowing through buildings—help maintain indoor comfort without relying on modern air conditioning. For example, in Seville, these methods keep indoor temperatures significantly lower than the outdoor heat, and similar principles are applied in hospitals using updated cooling technologies. Additionally, the article notes cultural adaptations like the revival of the siesta in Spain and government regulations mandating heat-related work breaks, emphasizing the need for humans to adapt to climate change rather than expecting the environment to adjust. It also references expert Lloyd Alter’s discussion on the importance of mean radiative temperature—the average temperature of surrounding surfaces radiating heat—as a critical factor in thermal comfort. Alter advocates for revisiting ancestral methods that effectively manage
energypassive-solar-designsustainable-coolingbuilding-materialsthermal-managementenergy-efficiencytraditional-architectureHot-cold design supercharges solar thermoelectric efficiency by 15x
Researchers at the University of Rochester have developed a novel "hot-cold" design that increases the efficiency of solar thermoelectric generators (STEGs) by 15 times, potentially bridging the gap between STEGs and conventional photovoltaic solar panels. Unlike traditional solar panels that rely on photovoltaic cells, STEGs generate electricity by exploiting the temperature difference between a hot side and a cold side through the Seebeck effect. Historically, STEGs have been limited by low efficiency, converting less than 1% of sunlight into electricity compared to about 20% for residential solar panels. The new approach improves efficiency not by altering semiconductor materials but by enhancing thermal management on both the hot and cold sides of the device. The innovations include using femtosecond laser pulses to etch nanoscale structures into tungsten on the hot side, creating a "black metal" surface that selectively absorbs solar wavelengths while minimizing heat loss. This surface is covered with a plastic layer that traps heat by limiting convection and conduction, effectively raising
energysolar-energythermoelectric-generatorsrenewable-energythermal-managementsemiconductor-materialsnanostructuresSEW-EURODRIVE supports heavy industry gearing with fast turnaround - The Robot Report
SEW-EURODRIVE has introduced externally assembled oil cooling and supply systems for heavy industry gearing, now produced at its Heavy Industry Gearing (HIG) facility in Wellford, South Carolina. This shift to local assembly significantly reduces lead times from 14–20 weeks to as short as six weeks, addressing previous delivery bottlenecks caused by reliance on global channels. These systems are designed to support torque-dense, compact gearboxes where thermal management is critical, ensuring efficient oil delivery, circulation, and cooling tailored for demanding industrial applications. The new external lubrication systems come in various configurations, including oil-to-air cooling (OAP1), oil-to-water cooling (OWP1), and pressure lubrication without cooling (ONP1), all sized using SEW-EURODRIVE’s thermal validation tools. They support startup oil viscosities up to 5,000 cSt and offer flexible mounting options for ease of maintenance. Additionally, the systems feature modular, sensor-ready components such as
robotenergyindustrial-automationthermal-managementlubrication-systemsgearbox-coolingSEW-EURODRIVEBreakthrough camouflage for soldiers copies plants, dodges enemy lasers
Chinese scientists from the Micro-Nano Optoelectronics and Intelligent Sensing Research Group at the National University of Defense Technology have developed an advanced multispectral camouflage device inspired by the infrared radiation characteristics of Rosaceae plants. Utilizing the phase change material In3SbTe2 (IST), the device achieves multifunctional capabilities including infrared camouflage, thermal management, laser stealth, and visible light camouflage. The design employs particle swarm optimization combined with finite difference time domain methods to optimize performance, enabling it to mimic plant emissivity in key atmospheric infrared windows (3–5 µm and 8–14 µm) and achieve ultra-low emissivity for stealth. The device demonstrates impressive results in both its amorphous and crystalline states, with emissivities closely matching those of natural leaves, thus effectively blending into infrared imaging. It also achieves high laser absorption rates at wavelengths of 1.064 µm, 1.55 µm, and 10.6 µm, enabling laser stealth capabilities. Thermal management
materialsphase-change-materialsinfrared-camouflagethermal-managementlaser-stealthoptoelectronicsmilitary-technologyRecycling breakthrough turns discarded Covid face masks into EV tech
Researchers from Australia and China have developed an innovative method to upcycle the vast quantities of discarded polypropylene (PP) Covid-19 face masks—estimated at over 950 billion since 2020—into high-performance nanocomposite films for electric vehicle (EV) electronics. The process involves cleaning and shredding used masks, coating the PP fibers with food-grade tannic acid to impart a negative charge, and then self-assembling positively charged graphene nanoplatelets around each fiber. A brief hot-pressing step fuses these into metre-scale films using only water and tannic acid under atmospheric pressure, making the method environmentally friendly and compatible with scalable roll-to-roll manufacturing. The resulting PP@G films exhibit exceptional thermal and electromagnetic interference (EMI) shielding properties, with thermal conductivity reaching 87 W/m·K—about 100 times higher than typical plastics—and EMI shielding effectiveness of 88 dB at 800 micrometers thickness, outperforming many advanced composites. These films can significantly
materialsrecyclingthermal-managementelectromagnetic-interference-shieldingnanocompositesustainable-materialselectronics-coolingUS firm's prototype induction pump tech to make nuclear reactors safer
NANO Nuclear Energy, a New York-based firm, has developed a prototype Annular Linear Induction Pump (ALIP) designed to improve thermal management in advanced nuclear reactors, particularly molten salt and liquid-metal reactors. Unlike traditional mechanical pumps, ALIP uses a time-varying magnetic field to move conductive fluids without mechanical components, which reduces wear, maintenance, and increases efficiency. The company has successfully integrated the ALIP technology into a controllable test loop at its Demonstration Facility in Westchester County, New York, marking a significant milestone in validating the pump’s design and performance. The development of ALIP is part of NANO Nuclear’s broader efforts to advance next-generation nuclear reactor technologies, with plans to begin commercial sales by late 2025 or early 2026. Current work focuses on refining the prototype, collecting manufacturing and performance data, and testing the pump with various fluids and failure scenarios. Collaboration with aRobotics Company has supported the fabrication and testing processes under the SBIR Phase III
energynuclear-energyinduction-pumpmolten-salt-reactorelectromagnetic-pumpthermal-managementadvanced-reactorsGoogle's geothermal experiments are engineering templates for the energy transition
Google is pioneering the integration of engineered geothermal systems (EGS) into its next-generation data centers to address the growing thermal and power demands driven by AI-scale computing. As AI workloads increase, traditional cooling methods like air cooling are becoming insufficient, especially with emerging high-performance chips such as Nvidia’s GB200, which generate significantly higher thermal loads. Google's approach involves leveraging subsurface heat as a stable, low-carbon energy source that can be engineered for dispatchability and scaled to meet the real-time power and thermal needs of hyperscale compute infrastructure. This initiative aims not only to provide near-constant carbon-free energy (CFE) for Google’s operations but also to serve as a scalable blueprint for the broader energy transition. Google’s geothermal efforts include two major projects: an enhanced geothermal system in Nevada developed with startup Fervo Energy, which employs advanced techniques like horizontal drilling and fiber-optic monitoring; and a corporate geothermal power purchase agreement in Taiwan with Baseload Capital, designed to deliver 10 MW of reliable power
energygeothermal-energyclean-energydata-centerscarbon-free-energypower-systemsthermal-managementFirst lab proof of Thomson effect marks major physics breakthrough
Japanese researchers have experimentally confirmed the transverse Thomson effect for the first time, validating a 174-year-old theoretical prediction in thermoelectric physics. This effect involves controlling the direction of heating and cooling flows by altering the direction of an applied magnetic field, differing fundamentally from the conventional Thomson effect. The team, led by Atsushi Takahagi and Ken-ichi Uchida, demonstrated this phenomenon using a semimetal alloy of bismuth and antimony (Bi88Sb12), chosen for its strong Nernst effect near room temperature. Their work, published in Nature Physics, revealed that unlike the conventional Thomson effect—which depends solely on the temperature derivative of the Seebeck coefficient—the transverse Thomson effect also depends on the magnitude of the Nernst coefficient, offering a new mechanism for active thermal management. The researchers overcame previous experimental challenges caused by competing thermoelectric effects (Peltier and Ettingshausen) by employing an infrared camera to isolate the thermal signals corresponding to the transverse Thomson effect.
energythermoelectricThomson-effectthermal-managementmaterials-sciencemagnetic-fieldthermoelectric-materialsThis electric scooter targets 100 mph record for world's fastest position
UK-based mobility company Bo has introduced the Turbo, a high-performance electric scooter designed to exceed 100 mph (160 km/h), aiming to set a new speed record for personal electric scooters. Although it visually resembles Bo’s 2023 M model, the Turbo is a result of 18 months of intensive development, featuring a powerful new powertrain with twin electric motors rated over 300A peak current and an 88-V, 1,800-Wh battery. Initial testing at Goodwood Motor Circuit demonstrated the Turbo reaching 85 mph (135 km/h) with acceleration comparable to a Tesla Model 3, suggesting a 0-60 mph time under 5 seconds. The scooter incorporates advanced engineering expertise from professionals with backgrounds in the Bloodhound World Land Speed Record project and Williams Formula One, along with collaboration from French company Rage Mechanics. The Turbo also includes sophisticated thermal management systems inspired by Formula One, such as brake duct inlets and ram-air induction to cool motor controllers, while its chassis
energyelectric-scooterelectric-motorsbattery-technologypowertrainthermal-managementurban-mobilityGerman firm's temperature prediction tech for motor boosts EV range
German automotive supplier ZF has developed an AI-based temperature prediction technology, TempAI, that significantly improves the accuracy of electric motor temperature forecasts by over 15 percent. This advancement enables more precise thermal management, allowing electric vehicles (EVs) to extract up to 6 percent more peak power and achieve verifiable efficiency gains during standardized WLTP driving cycles. The technology also reduces energy consumption by 6 to 18 percent under dynamic driving conditions, such as on demanding tracks like the Nürburgring Nordschleife. TempAI operates without requiring additional hardware, relying solely on AI models that use existing control units with low computational demands, making it cost-effective and ready for series production in ZF’s new generation of electric motors. The AI platform automatically generates physically based models from extensive measurement data, capturing complex internal motor processes that are otherwise difficult or costly to measure directly. Beyond performance benefits, TempAI contributes ecological advantages by enabling optimized thermal designs that reduce the use of heavy rare earth materials and short
energyelectric-vehiclesAI-technologyelectric-motorstemperature-predictionthermal-managementefficiency-optimizationNext-gen coating mimics clouds to manage heat, evade detection
Researchers at Finland’s Aalto University have developed an innovative wafer-thin “cloud” metasurface coating that can dynamically switch between bright white and deep grey states, enabling surfaces to either cool by reflecting sunlight or heat by absorbing it, all while remaining nearly invisible to infrared (thermal) cameras. This dual-function coating mimics the behavior of cumulus clouds, adapting its optical properties to manage heat passively and without energy input. Unlike traditional white paints that cool by scattering sunlight but become conspicuous in thermal imaging, or black surfaces that absorb heat but emit strong infrared signals, this metasurface maintains very low mid-infrared emissivity (8–13 microns), effectively camouflaging heat signatures in both modes. The coating’s unique performance arises from a disordered array of metallic nanostructures that manipulate light through multiple scattering and “polarizonic reflection.” In the white state, solar photons are reflected back into space, providing radiative cooling under full sun, while in the grey state,
materialsnanotechnologysmart-coatingsthermal-managementinfrared-camouflageenergy-efficiencymetasurfacesChina's new 2.47kW portable laser works in Arctic cold, Saharan desert
Chinese scientists at the National University of Defence Technology have developed a portable 2.47-kilowatt fiber laser weapon capable of operating in extreme temperatures ranging from -58°F (-50°C) to 122°F (50°C) without requiring cooling or heating systems. This innovation allows the laser to function effectively in diverse environments, from the Arctic to the Sahara Desert, overcoming the typical need for bulky cooling infrastructure found in most high-power lasers. The laser achieves this through several technological advancements, including a novel low-heat pump laser design, smart multi-directional light injection, thermal isolation of sensitive components, tight fiber cooling to suppress energy loss, and a ytterbium-doped fiber core that efficiently converts energy into laser light with 71% efficiency. With near-perfect beam quality at 2.47 kW output, the laser can disable drones and cut through various materials from over 0.62 miles (1 km) away. Its portability—small enough to fit in a suitcase—offers significant
energyfiber-laserportable-laserytterbium-doped-fiberthermal-managementlaser-weapondefense-technologyPassive tech sets cooling record for overheating AI data centers
Engineers at the University of California, San Diego have developed a groundbreaking passive cooling technology for data centers that sets a new record by handling over 800 watts per square centimeter of heat dissipation. This fiber-based cooling system uses a specially engineered membrane with interconnected pores that passively removes heat through evaporation, eliminating the need for energy-intensive fans, compressors, or pumps. Unlike traditional cooling methods, this approach leverages capillary action to wick liquid across the membrane surface, where evaporation naturally draws heat away from electronic chips, offering a quieter and more energy-efficient alternative. The innovation addresses longstanding challenges in adapting evaporative cooling to the extreme thermal loads of modern AI data centers, where conventional porous membranes either clogged or caused unstable boiling. By optimizing pore size and reinforcing the membrane mechanically, the UCSD team achieved stable, high-performance cooling over multiple hours. While the technology currently operates below its theoretical maximum, efforts are underway to integrate it into cold plates for direct processor cooling and to commercialize the solution through a startup
energycooling-technologydata-centerspassive-coolingfiber-membranethermal-managementenergy-efficiencyThe All-New Nissan LEAF: A Perfect Blend of Performance, Comfort, and Efficiency - CleanTechnica
The third-generation Nissan LEAF introduces significant enhancements in performance, comfort, and efficiency, highlighted in the second installment of Nissan’s LEAF Insights video series. The new model features Nissan’s all-new, compact 3-in-1 electric powertrain, which is 10% smaller than its predecessor and delivers up to 160 kW (214 hp) and 355 Nm (261 ft-lb) of torque on select variants. This powertrain, combined with a multi-link rear suspension system that increases lateral stiffness by 66%, a more rigid body structure, and the CMF-EV platform, results in improved agility, ride comfort, and a tighter turning radius of 5.3 meters despite larger 19-inch wheels. Additionally, noise and vibration reductions make the cabin up to 2 decibels quieter at urban speeds compared to the previous generation, with a redesigned HVAC unit placement enhancing interior spaciousness. Thermal management is a key focus in the new LEAF, with engineers implementing a liquid-cooled battery system that incorporates a thermal recovery feature. This system captures heat generated by the on-board charger to warm the battery, improving regeneration efficiency and maintaining optimal battery performance in cold conditions, which can help extend driving range. Overall, the integration of the advanced powertrain, thermal management, upgraded suspension, and platform improvements deliver a smooth, responsive, and energy-efficient driving experience. Further details will be revealed in the final installment of the LEAF Insights series.
energyelectric-vehiclesbattery-technologythermal-managementelectric-powertrainenergy-efficiencyautomotive-innovationDow’s Collaboration With Jaguar TCS Racing At Miami E-Prix — A Focus On Thermal Management
energythermal-managementFormula-Ecollaborationelectric-vehiclessustainabilityDow