CooliBlade NEOcore: Cost Efficiency in Power Electronics Cooling

This post is fifth part of our new blog series on NEOcore, game-changing power electronics cooling technology (to read the previous ones, click here:, Problems and Challenges of Power Electronics Cooling) . With these posts, we’ll dive deeper into the technological innovations, unique features, and practical customer benefits of NEOcore technology. You’ll get an inside look at real-world use cases - with actual, measured results from real power electronics projects. Expect to see significant performance boosts, impressive energy savings, reduced device weight, improved end products, and even increased market share.

CooliBlade NEOcore: Cost Efficiencient Thermal Management as a Business Advantage

Effective thermal management impacts far more than just component reliability — it influences the entire hardware architecture and, in many cases, the competitiveness of the entire product portfolio. Companies that adopt advanced power electronics cooling technologies earlier than their competitors gain a significant lead, benefiting from both technical advantages and commercial synergies.

When analyzing total cost of ownership, CooliBlade solutions consistently outperform conventional cooling technologies — especially when considering the full cooling system costs across production, logistics, and long-term operation. The higher the production volumes, the greater the economic advantage of CooliBlade.

Superior Performance = Lower Lifecycle Costs

By delivering superior thermal performance and maintaining lower component operating temperatures, NEOcore™ cooling technology help:

• Extend the lifespan of power electronics modules (IGBT, SiC), PCBs, and thermal interface materials
• Minimize derating requirements, ensuring products maintain full rated performance
• Reduce costly failures that can impact both OPEX and brand reputation

Material Advantage: Aluminum vs. Copper

Most conventional heat pipes rely on copper, which is costly and complex to manufacture at scale. CooliBlade takes a different path:

• Aluminum-based cooling ensures low thermal resistance, high conductivity, and easy availability.
• From a material cost perspective, aluminum is significantly more cost-effective than copper.
• At high production volumes, this advantage multiplies, making NEOcore-based solutions the most cost-efficient alternative in the power electronics cooling market.

Compact Design = Material and Logistics Savings

CooliBlade heat sinks are structurally optimized:

• Hollow-core and compact design reduces raw material usage.
• Up to 50% lighter than standard aluminum heat sinks.
• Direct cost savings across the value chain: aluminum billets, refining, transport, warehousing, and final assembly – plus additional savings from lower maintenance costs thanks to reliable, sealed system: no pumps, no leaks, no scheduled maintenance.

For customers, these savings also extend to product design benefits:

• Smaller, lighter housings for complete devices.
• In some cases, fewer frames needed across product families with multiple power ranges.
• Greater flexibility in IGBT and SiC module selection, enabling further cost reductions.

Production Methods for Cost-Efficiency

CooliBlade uses carefully selected manufacturing processes to balance performance and cost:

• Aluminum extrusion → produces complex cross-sections efficiently, cut to length, activated, and tested.
• ULTIMA heat sinks → modularly assembled in three fluent stages with semi-automated stations.
• One semi-automated line = up to 100 000 units/year.
• Full automation = capacity can double quickly.

This scalable production approach ensures cost efficiency at low, medium, and high volumes — supporting power electronics designers across industries from renewable energy and EV charging to industrial drives and telecoms.

Conclusion: Competitive Advantage Through Cooling Innovation

CooliBlade’s cost-efficient cooling technology not only enhances thermal performance but also enables measurable savings in materials, logistics, production, and product lifecycle costs.

By combining aluminum-based innovation, compact structural design, and scalable European manufacturing, NEOcore cooling technology help customers achieve:

• Up to 50% power improvement
• Up to 50% lower cooling system weight
• Up to 25 °C lower component temperatures
• Faster, more cost-efficient scaling of production

As electrification accelerates globally, cost efficiency in power electronics cooling is becoming a decisive factor for OEMs. With CooliBlade, customers gain both a technological edge and a commercial advantage in the race toward more powerful, reliable, and sustainable systems.

Stay tuned for the last part of NEOcore series as we dive deeper into the innovations and real-world results of NEOcore technology. We’ll explore more technological breakthroughs, features, benefits, and customer success stories.

Ready to keep your cool? Learn more how CooliBlade can help you design the future of power electronics - Contact our cooling experts

Learn more about NEOcore cooling technology