CooliBlade Development Services

Development services

Thermal management solutions are integral to power electronics product development, and multiple aspects must be considered. Proper thermal management design significantly impacts product performance, lifespan, and environmental footprint. Limited space, variable mounting position, high power levels, and environmental requirements such as vibration and moisture are frequent design challenges limiting the possibility of using standard cooling modules.

CooliBlade Development Services aids you in product development by offering a straightforward path from a first evaluation to testing with a working prototype and swiftly entering the actual production phase. This streamlined development process ensures you can direct your focus to product development while we solve your thermal management needs.

01

A quick feasibility check

The first phase of CooliBlade’s development cycle is to estimate whether NEOcore technology suits your case. You can specify your needs using our free evaluation tool, and our thermal management experts will give you quick feedback about the performance and feasibility. In the evaluation, we calculate the thermal budgets based on your specifications and compare them and possible design constraints to NEOcore’s technical performance.

02

Concept design and thermal simulation

The second step is to create a concept design for the thermal management solution. The outcome is a first cooling concept in which NEOcore cooling performance is adapted to the customer-specific requirements, including product size and form factor, component layout, and usage environment.

Thermal simulation is one of the critical phases when developing cooling solutions for power electronics. In the thermal simulation, CFD (Computational Fluid Dynamics) and heat transfer equations are combined in FE (Finite Element) modeling to calculate the cooling performance based on physics. By comparing simulation results of different concepts, the best can be quickly chosen. The simulation model calibrated with the real-world measurements of NEOcore products allows us to estimate the heat dissipation capability of the existing system.

03

Prototype design and manufacturing

When the concept studies and simulations confirm the feasibility and initiative performance of the NEOcore design, it is time to enter the prototype design phase. CooliBlade’s design engineers and thermal management experts work together to find the best solution from both cooling performance and manufacturability points of view. The design can be rapidly iterated using thermal simulations to reach the best possible performance. Our seamless development process includes a quick transfer from the design phase to the production of prototypes. Typically, the prototype manufacturing and assembly take 2-4 weeks after finishing the design phase.

04

Prototype testing and evaluation

The final step in prototype development is testing and confirming the device’s performance in the laboratory or customer test environment. CooliBlade has extensive laboratory measurement systems available for comprehensive performance testing of the prototypes. The laboratory measurement systems can be used for natural and forced convection cases where the environment can be controlled and temperatures monitored via a fully automated cloud-based data logging system. The test can be conducted in two phases: the CooliBlade technical team does the first tests, and the final tests are carried out at the customer site.

05

Production ramp-up

Typically, one more design iteration round is needed based on prototype test results. It is the DFM (Design for Manufacturing) phase, where the design is fine-tuned and optimized for high-volume manufacturing. The outcome of the DFM round is a production-ready design where all the production documents and test procedures are defined together with the customer. The production ramp-up phase includes pilot batch delivery and testing before the final production ramp-up and higher volume deliveries.