3D-printed evaporator for data centre cooling
4th February 2026
DENMARK: A European research project has used 3D-printing technology in the development of an energy-saving passive two-phase thermosyphon cooling solution for data centres.
In the recently concluded AM2PC project, the Danish Technological Institute and Danish thermal management company Heatflow, together with two international partners, have developed and tested a 3D-printed evaporator – the key component of the thermosyphon system.
The thermosyphon method uses natural convection and gravity to circulate fluids (liquids or gases) without mechanical pumps.
The new solution differs from conventional air cooling by using a coolant that evaporates at the hot surface. The vapour naturally rises due to differences in density, condenses elsewhere (where it releases heat), and returns as liquid through gravity. According to the developers, the system could significantly reduce energy consumption for cooling in data centres.
The latest development has achieved a cooling capacity of 600W in tests – 50% more than the original target of 400W.
The use of 3D printing for the aluminium evaporator allows all necessary functions to be integrated into a single part. This eliminates assembly points, reduces the risk of leaks, and makes the component more reliable.
The AM2PC research project was focused on developing a 3D-printed component for two-phase cooling of data centres. The project was supported by M-ERA.NET, European network of public funding organisations, and included funding from Innovation Fund Denmark. In addition to Heatflow ApS and Danish Technological Institute, Open Engineering from Belgium and Fraunhofer IWU from Germany also participated. Project funding of €942.186 contributed to the total project costs of €1.353.321.
A central result from the project was that the solution was proven to remove heat at temperatures between 60ºC and 80ºC. When heat is extracted at such high temperatures, it can be used directly in the district heating network without additional energy input, but it could also be used for other industrial processes.
“In the project, we did not focus on the integration with district heating itself, but we have demonstrated that the technology enables it,” said Simon Brudler, 3D-printing specialist and senior consultant at the Danish Technological Institute. “This is an important step toward more energy-efficient data centeres that can contribute positively to the overall energy balance,” he added.
Besides the energy savings during operation, the project also shows environmental benefits in manufacturing. By using 3D printing, the overall material usage is reduced compared to conventional solutions that consist of several components made of different materials.
And since the component is produced from a single material, it can be more easily recycled at the end of its lifetime.
Life cycle analyses indicate that the solution could reduce total emissions by 25% to 30% per unit.
