Additive Manufacturing

Innovating 3D Printed Structures to Advance Thermal Management Solutions


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Additive Manufacturing is a method of fabrication gaining popularity as 3D printers advance to accommodate a wider range of materials. The Additive Manufacturing Team at Aavid, Thermal Division of Boyd Corporation is composed of experienced engineers in both thermal and additive design. Our team leverages advanced process knowledge to design and print functional parts that other companies cannot.

We specialize in designing and fabricating thermally efficient, complex products that would be impossible to manufacture using traditional subtractive metal fabrication processes. Our thermal designers simulate forces, pressure drop, and thermal performance of our printed designs during planning and design stages to meet your demanding application requirements. We print primarily with AlSi10Mg and a 6061-RAM2 powder which mimics the mechanical characteristics of Aluminum 6061-T6, the popular wrought alternative.

Additive Manufacturing, or 3D Printing, enables faster lead times by eliminating the need for fixtures and limiting setup time that accompanies more traditional metal fabrication processes. 3D Printed parts combine what would be multiple manufacturing processes for a complex product into a single print, reducing lead times from months to days. Since we use real time monitoring of ongoing prints, we identify manufacturing risks and potential defects sooner, allowing you to more tightly maintain your supply chain schedules.

Aavid’s Additive Manufacturing Team expertise includes design, simulation and reliable 3D printing of:

  • Heat Exchangers
  • Liquid Cold Plates
  • Two Phase Cooling such as Heat Pipes and Vapor Chambers
  • Advanced Heat Sinks


The Aavid Engineering team has spent years improving Additive Manufacturing processes to attain better geometries for improved performance of products such as:

  • Wicking Structures, internal pores, or capillary flow paths for either liquid or two phase cooling.
  • Thinner Walls
  • Custom Lattices and Fins
  • Variable Surface Finishes

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