Jet engines get incredibly hot and need cooling systems, but those coolers are heavy — and every extra kilogram on an aircraft burns more fuel. This project used 3D printing to build an air-oil heat exchanger that handles 80kW of heat while weighing significantly less than 10kg — far lighter than what's currently available. Think of it like replacing a bulky cast-iron radiator in your house with a sleek, custom-shaped aluminium one that works even better. They built and tested two working demonstrators ready to move toward flight testing.
Aircraft engines need powerful cooling systems, but conventional heat exchangers are heavy and bulky — and in aerospace, every kilogram costs fuel and reduces range. Next-generation geared turbofan engines (VHBR/UHBR) demand even higher cooling performance in even tighter spaces. Engine manufacturers need compact thermal solutions that deliver high heat loads without the weight penalty.
The team designed and manufactured two demonstrator air-oil heat exchangers using additive layer manufacturing (industrial 3D printing). These units deliver 80kW heat load at significantly less than 10kg dry weight, validated at TRL 6 with thermal modelling and performance testing against Clean Sky 2 requirements.
If you are an engine manufacturer struggling to meet weight and efficiency targets for next-generation geared turbofan engines — this project developed a 3D-printed air-oil heat exchanger delivering 80kW cooling at significantly less than 10kg dry weight. Two validated demonstrators were built at TRL 6, ready to feed into flight demonstrator programmes.
If you are an additive manufacturing company looking to prove your technology in high-value aerospace applications — this project demonstrated that complex heat exchanger geometries can be reliably manufactured using additive layer methods. The consortium of 3 UK industry partners validated the process through 2 demonstrator builds with in-build test results.
If you are a thermal management company dealing with the challenge of delivering high heat loads in tight spaces — this project proved that additive manufacturing can produce compact heat exchangers handling 80kW in a package weighing less than 10kg. The design and validation methods could transfer directly to other high-performance cooling applications.
The project received EUR 1,191,905 in EU funding across 3 industrial partners to develop and validate the technology. Production costs for additive-manufactured heat exchangers depend on material, build volume, and certification requirements. Based on available project data, detailed per-unit cost breakdowns are not published.
The project targeted TRL 6 and MRL 6 (Manufacturing Readiness Level 6), which means the manufacturing process was demonstrated in a production-relevant environment. Two demonstrator units were built with documented in-build test results. The objective explicitly states the design should flow into follow-on flight demonstrator and new product introduction programmes.
The project was led by Meggitt Aerospace Limited, a major aerospace components manufacturer. As an Innovation Action with 100% industry consortium, the IP is likely held by the industrial partners. Licensing discussions would need to go through Meggitt directly.
The project objective states the target is a dry weight of significantly less than 10kg while handling 80kW heat load — designed for next-generation geared VHBR/UHBR turbofan engines. Additive manufacturing enables geometries impossible with conventional fabrication, allowing better thermal performance in a smaller, lighter package.
The project included performance testing and thermal model validation. Two demonstrator units were manufactured with associated in-build test results documented. The design was validated in line with the Topic Manager's (Clean Sky 2) requirements at TRL 6.
The project closed in October 2022 with demonstrators at TRL 6. The objective states the validated design should flow directly into flight demonstrator and NPI programmes. Based on available project data, the next step would be TRL 7-8 flight testing, which typically takes several additional years in aerospace.
This is a tightly focused, all-industry consortium of 3 UK partners led by Meggitt Aerospace Limited, a well-established aerospace components manufacturer (not an SME). With zero universities or research organizations and 100% industry participation, the project was clearly execution-oriented — building and testing hardware, not publishing papers. The single-country setup (all UK) simplified coordination. For a business looking to engage, this means the technology was developed by companies that understand manufacturing realities and certification requirements, not just lab conditions.
Meggitt Aerospace Limited (UK) — reach out to their thermal management or advanced manufacturing division
Want an introduction to the C-ALM AOHE team? SciTransfer can connect you with the right people at Meggitt Aerospace to discuss licensing, partnership, or technology transfer.
