AI Design & Additive Manufacturing
YOUR HUB FOR INSIGHTS INTO THE LATEST ACHIEVEMENTS IN LIQUID COOLING TECHNOLOGY
Here, you’ll discover how our AI-driven designs and advanced additive manufacturing techniques are revolutionizing liquid cooling performance for data centers, AI & high-performance computing, and industrial applications. Explore the innovation behind our solutions and learn how ZeroKelvin is setting a new standard in thermal management.
COOLING DESIGNED BY AI
Comparison: Skived Design vs AI-Optimized Design
INTRODUCTION
Cold plate design directly influences thermal efficiency, reliability, and long-term operating costs. While skived design has been used for decades, it is limited in geometry, performance, and durability. At ZeroKelvin, we combine AI-driven optimization with additive manufacturing to deliver cold plates that set a new benchmark for advanced thermal management.
Conventional skived design
AI thermal topology optimization
Limitations:
Restricted to simple, repetitive fin geometries.
Unable to direct coolant flow to thermal hot spots.
Higher pressure drop due to inefficient flow paths.
Vulnerable to clogging because of narrow channels.
Bottom line: A basic option unsuitable for demanding applications that require precision cooling.
DEFINITION: Skived cold plates are produced by mechanically shaving thin fins into a solid block of metal.
WHAT IS AI-OPTIMIZED DESIGN WITH ADDITIVE MANUFACTURING?
Definition: At ZeroKelvin, we use AI algorithms and computational fluid dynamics simulations to design cold plates with complex internal structures. These advanced designs are manufactured using additive manufacturing technologies, which allow us to create geometries impossible to achieve with traditional methods like skiving.
ADVANTAGES
Unconstrained geometry → additive manufacturing enables organic channel structures tailored to each application.
Superior thermal performance → AI optimization directs coolant flow exactly where heat is concentrated.
Lower pumping losses → optimized channels reduce pressure drop and save energy.
Leak-proof unibody construction → additive manufacturing allows production of cold plates without brazing or sealing elements.
Sustainability → less waste material, longer product lifetime, and lighter components.
Bottom line: The combination of AI and additive manufacturing delivers unmatched performance, reliability, and flexibility.
Metal fusion technology
WHY ZERO KELVIN CHOOSES AI + ADDITIVE MANUFACTURING
At ZeroKelvin, skived design is considered outdated. Modern applications such as HPC processors, EV inverters, radar systems, and next-generation GPUs demand solutions that only AI-optimized cold plates produced with additive manufacturing can deliver.
Lower temperatures → higher efficiency
Reduced pumping energy → lower operating costs
Leak-proof single-body design → maximum reliability
Sustainable manufacturing → less waste, lighter design, longer lifetime
With ZeroKelvin’s approach, you are not constrained by traditional manufacturing methods. Instead, you gain access to future-proof thermal solutions engineered for the most demanding environments.
AI driven thermal design
Side-by-Side Comparison
KEY BENEFITS
1. ENHANCED THERMAL PERFORMANCE
Improvement of 25% compared to conventional skived coldplates. Better thermal performance is achieved using conjugate heat transfer topology optimization – a method that enables us to specifically optimize internal cooling structures to achieve both best possible heat convention and conduction. Optimization strategy targets silicon hotspots, optimizing for both temperature uniformity and minimizing temperature peaks in the next generation heat sinks.
Measured thermal and hydraulic performance on ZeroKelvin’s AMD-SP5-W-R03 socket at rated 500W TDP
ZeroKelvin coldplates are engineered for efficiency in the data centers meaning they can reduce pressure differential by up to 70% (measured)! Resulting in lower energy consumption and less pumping losses. Our 500 μm+ channel is wider than industry standard of 150 μm common with skiving design approach, which drastically reduces pumping losses without compromising on heat transfer.
2. REDUCED PRESSURE DROP
PRESSURE DROP: 7500 Pa
@ 1 l/min, R=0.024 K/W
PRESSURE DROP: 2200 Pa
@ 1 l/min, R=0.0174 K/W
ZeroKelvin’s single phase DLC apply targeted, heat-map-guided cooling to address the most thermally demanding zones inside high-density hardware.
By focusing directly on critical areas, this approach eliminates hotspots, delivers superior thermal performance, and achieves a more uniform temperature distribution across the system.
3. PRECISION UNIFORM COOLING
TEMPERATURE VARIANCE: 1.3K²
TEMPERATURE VARIANCE: 6.7K²
ZEROKELVIN CU- R SP5
AI TOPOLOGY OPTIMIZATION
A SIMPLE SKIVED DESIGN IS NOT FLEXIBLE FOR MODERN GPU NEEDS
-80% temperature variance
Designed to combat clogging, our wide channels ensure consistent flow even in demanding conditions, maintaining optimal cooling efficiency over time, further improving durability and longevity and reducing maintenance. Our 500 μm+ channel is wider than industry standard of 100-300 μm and minimal channel cross section increased by up to 180%.
4. ELIMINATED RISK OF CLOGGING
CHANNEL WIDTH
ZERO KELVIN SP5
CONVENTIONAL SKIVED COLDPLATE
500 μm+
100 - 300 μm
CHANNEL AREA CROSS SECTION
ZERO KELVIN MI200 / SP5
CONVENTIONAL SKIVED COLDPLATE (100 μm)
0.8 mm²
0.2 mm²
Singe body cold plates feature a robust, leak-proof, construction tested to withstand pressures up to 20 bar, four times higher than minimal requirement by OCP, ensuring long-term, dependable operation in critical environments. As a results of proprietary additive manufacturing process, we are to design single body coldplates with no sealing elements or additional bonding parts. All the materials used within the manufacturing process for the ZeroKelvin CU product line are compatible with OCPs recommendations. Compared to conventional vacuum brazing products, ZeroKelvin’s cold plate can withstand significantly higher pressure loads. Every part manufactured is validated using both ultrasonic inspection and a helium gas leak test. Wider than industry standard of 150um, helping us achieve many of the flow advantages.
5. LEAK-PROOF UNIBODY DESIGN
Resistant to 20 bar
Our unique approach to manufacturing means that we are not constrained by conventional manufacturing methods. We are able to make quick design changes and individually adapt to customers' more specific requirements regarding external part geometry, inlet/outlet positions, thread types, or even cooling requirements. In addition to flexible design, we have the highest throughput of any comparable additive manufacturing process, and our system is streamlined for large-series manufacturing.
6. DESIGN FLEXIBILITY
Lightweight full-metal slim design ready for tight 1U mounting applications. ZeroKelvin cold plates are up to 28% lighter than competing products without sacrificing performance or durability.
