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KW Micro Power Creates Lightweight Multifunctional Microturbine Housing with Embedded Cooling Channels
Technology Category
- Other - Additive Manufacturing
- Functional Applications - Product Lifecycle Management Systems (PLM)
Applicable Industries
- Aerospace
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Additive Manufacturing
Services
- Software Design & Engineering Services
- System Integration
The 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 The 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.
The 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.
Operational Impact
Quantitative Benefit
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