Alloy Enterprises and its Stack Forging process has introduced a new copper direct liquid cooling (DLC) solution as it looks to revolutionise data centre cooling.
The technology is an alternative to 3D printing metal, allowing manufacturers to use already qualified and widely available aluminium – and now copper – to build their designs sheet-by-sheet, allowing for conformal cooling channels to be incorporated at a much lower cost.
Alloy Enterprises Stack Forging process allows for a build volume of 300 x 250 x 200mm, creating a single-piece construction that eliminates leak points common in traditional liquid cooling systems.
With chip power densities pushing AI server rack power densities beyond 120 kW, the Alloy Enterprises solution sidesteps traditional cooling methods and the need for HVAC. Instead it uses targeted liquid cooling where heat loads are highest, with a 10-times reduction in pressure drop, enabling smaller pumps and energy savings.
“Alloy Enterprises is setting a new standard in direct liquid cooling technology with our proprietary Stack Forging process,” said Alloy Enterprises CEO Ali Forsyth.
“We now deliver industry-leading thermal performance in both aluminium and copper, enabling higher rack densities, significant cost savings and greater sustainability. With 600 kW racks on the horizon, the shift to liquid cooling is no longer optional – it’s mission-critical!”
Alloy says that its Stack Forged DLCdata centres can use 44°C water and smaller pumps, eliminating the need for refrigerated HVAC systems. The result is a reduction in data centre energy consumption by up to 23 per cent, dramatically improving both sustainability and profitability.
The process also adds to a fully sustainable supply chain: 100% of aluminium and copper scrap generated during manufacturing is easily recycled, reinforcing the long-term environmental and economic value of the process.
