New Swedish production technology for effective production of Non-metallic Liquid Cold Plates
By upgrading the conventional extrusion process with inline precision forming, it is now possible to manufacture flow plates with complex geometries in a single continuous step and achieve high production rates at a fraction of the processing cost.
Figure 1: Reliefeds proprietary z.trusion® process applies to both liquid cold plates and heat-exchanger-style flow plates; the examples shown illustrate that shared principle
It is the Swedish manufacturing company Reliefed that has developed and patented a manufacturing method that offer a new approach to how non-metallic flow plates can be produced and used for liquid cold plates, thermal and electrochemical systems.
This approach removes both design and scalability barriers that have previously limited the use of composites, technical ceramics and polymers in thermal applications. The result is a highly efficient production method that opens new material possibilities, reduces manufacturing costs, and supports the industry’s shift toward lower carbon, corrosion and fouling resistant solutions.
Figure 2: Aluminum nitride material, a high-performance ceramic material valued for its exceptional thermal conductivity, electrical insulation, and corrosion resistance.
Moving beyond metal
Liquid cold plates are critical for thermal management, but most are still built from metals like copper, aluminum, or stainless steel. While these are strong and familiar, they come with clear drawbacks: heavy weight, high cost, energy-intensive production, and vulnerability to corrosion and fouling over time. In many applications, metals are a compromise, chosen because suitable alternatives haven’t been available at cost efficient scale.
Non-metallic materials such as graphite composites and technical ceramics can solve many of these issues, offering lower weight, improved corrosion resistance, and cleaner operation. The challenge has been manufacturing. Traditional molding or machining methods make production slow and expensive, limiting the use of these materials. Reliefed’s technology changes this by producing 3D structured non-metallic plates in seconds, enabling faster, more efficient manufacturing.
As performance and sustainability demands grow, shifting beyond metal becomes not just relevant but necessary for the future of cold plate design.
A new approach to extrusion
The patented process, named as z.trusion®, retrofits directly onto existing extrusion lines. Using custom tooling and a rotating shaping element, the method continuously forms flow channels into extrudable materials. This enables single-step production of three-dimensional plate geometries without additional machining, pressing, or secondary handling.
Figure 3: Principle of Reliefed’s patented production technology using rotating elements to form extruded profile in 3 dimensions in one single step
The process is material agnostic and has been validated for use with a range of highly conductive materials such as graphite composites and technical ceramics (silicone carbide and aluminum nitride) but also for regular polymers used for example as turbulence enhancing inserts.
Figure 4: An example of the structures possible using Reliefed’s production technology
Technical performance and design freedom
One of the advantages of the technology is the design freedom it enables. When compared to conventional metal stamping the process supports sharper release angles and asymmetric geometries, such as different designs on each side of the plate. Unlike injection molding, the plate dimensions are not constrained by the need to fill a mold cavity from a central gate. The in-line forming approach removes these flow limitations, allowing for a wider choice of materials and greater flexibility in plate size.
Figure 5: CFD analysis of battery cooling pack profile developed by Reliefed providing fixation for cells, lightweight optimization, modularity and tab cooling.
A major cost-efficiency driver is the modularity of the tooling. By incorporating interchangeable or rotating elements, a single tool can produce a variety of flow patterns for the same plate size. This makes it possible to tailor designs to specific application needs without the high costs and long lead times typically associated with custom tooling. From a technical standpoint, the plate has shown strong potential to meet system requirements in both simulations and real-world testing.
Environmental considerations
Non-metallic cold plates offer a significantly lower carbon footprint compared to metal alternatives. Metals require energy-intensive extraction, melting, and forming, while polymer and composite materials can be processed with far less energy. Reliefed’s continuous forming technology further reduces environmental impact by operating at lower temperatures and using less energy per part than conventional methods like machining or injection molding.
In addition, the use of corrosion-resistant materials extends product life and reduces maintenance needs over time. This not only improves system reliability but also contributes to lower total emissions across the full lifecycle of the product.
From pilot to production
Reliefed has already worked with partners in the energy and transportation sectors, including a large Global Heat Transfer leader, Volvo Group, and Polestar, to test and validate its plate technology for various flow plate designs. The cases span applications in hydrogen fuel cells, battery cooling, and heat recovery from aggressive fluids.
Initial sample deliveries began in April 2025, with pilot capacity based in Varberg, Sweden. A larger rollout is expected to follow in 2026 with internal capacity for high volume plate production serving customers’ needs to scale fast.
Source: reliefed.com