Innovative Additive Manufactured Heat Exchangers for Industrial Applications

Presentation by Dr. Ing. Cassidy Silbernagel, Sr. Additive Manufacturing Mechanical Engineer at Exergy Solutions as part of Altair's Simulate at the Speed of Design 2025 conference.

This presentation will cover the collaborative work between Altair and Exergy Solutions on the design, analysis, and development of lattice-filled, additively manufactured heat exchangers intended to replace traditional shell and tube configurations. A simulation-driven design workflow utilizing implicit modeling technologies optimizes the weight, size, and reliability of these exchangers. The session will demonstrate how Altair Inspire workflows customize lattice geometries through field-driven design, using simulation results and test data to refine structures for specific applications. The parametric Design for Additive Manufacturing (DfAM) approach employed showcases potential cost savings and performance enhancements. Additionally, Exergy’s use of high wear-resistant Vibenite materials for 3D-printed components highlights advancements in durability and fatigue resistance, underscoring the potential for AM in wear-intensive industrial settings. Attendees will learn about the integration of additive manufacturing, advanced software, and digital supply chain strategies in developing cutting-edge heat exchanger technology aimed at supporting net-zero industrial goals.