Engineering the Unfair Advantage

For all thermal system requirements, PWR is your development and innovation partner to help design, develop, manufacture and test all cooling solutions by; “Engineering The Unfair Advantage”

Building on our existing AS9100D certification, PWR is pleased to advise that it has secured Nadcap® Accreditations for its chemical processing and heat treating applications.

Markets and Innovation

Motorsport

PWR Advanced Cooling Technology have been supplying bespoke cooling solutions to the motorsports world for over 20 years. In its infancy, PWR was born from a need for better quality and performance radiators and oil coolers in the domestic V8 racing series. PWR quickly gathered momentum and became the market leader.

Defence

PWR group, including our Australian, US and UK sites provide design, manufacture, full system integration and testing of cooling systems for the defence sector. Our products include a wide variety of heat exchanger assemblies, thermal management solutions and additive manufactured components for propulsion systems, power electronics and energy storage. Our USA facility is ITAR registered and our Australian site exports product with several primes globally.

OEM

PWR are a supplier of cooling products to the OEM road car market and specialise in complete car solutions including ICE, hybrid and full electric cooling. Production volumes range from one off special vehicles, through to niche projects providing 20-30k vehicle sets per year.

Aerospace

PWR group, including our Australian, US and UK sites provide design, manufacture, full system integration and testing of cooling systems for the Aerospace sector. Our products include a wide variety of heat exchanger assemblies, thermal management solutions and additive manufactured components for propulsion systems, power electronics and energy storage. Our USA facility is ITAR registered and our Australian site exports product with several primes globally.

Electric and Hybrid

PWR specialize in custom liquid cooling products such as energy storage systems, power electronics cooling and heat exchange for battery and electronics applications. PWR also supply complete autonomous vehicle cooling solutions including dielectric cooling and compute cooling liquid cold plates for electronic systems in self-driving vehicles for automotive and aerospace.

Performance Aftermarket

PWR are global leaders in the design and manufacture of high-performance aftermarket cooling components to suit all makes and models. We have been supplying the Performance Aftermarket industry with cutting edge cooling components for over 20 years and pride ourselves on working with our customers to develop products that deliver the highest level of performance and quality.

Renewable Energy

PWR work with several companies in the renewable energy sector. With ever growing targets on the production of clean energy through wind, water and solar power generation, PWR have aligned with several pioneering projects to supply cooling products for motor generator units (MGU’s) and power electronic cooling, using liquid cooling plates.

Industrial

PWR have been supplying the industrial market for over 20 years. Applications for our products include commercial ICE and electric buses, general haulage trucks, heavy mining equipment, industrial drying machines, autonomous mining and recovery vehicles as well as many more.

Our Products

Tube and Fin Heat Exchangers

Our extensive experience and years of research and development in tube & fin heat exchanger technology has allowed PWR to develop fully customisable heat exchangers that can be tailored to extract the best performance for your application.

Bar and Plate Heat Exchangers

Along with producing tube & fin style heat exchangers PWR also has a wide-ranging ability in producing bar & plate style heat exchangers. Typically known for their increased robustness and durability innate to its design PWR has a wide range of bar and plate construction options that can be tailored to meet a project’s requirements and optimise performance.

Additive Manufacturing

PWR have high temperature polymer SLA and aluminium powder DMLS additive manufacturing machines in house, which together with specific technical agreements, allows us to produce world leading aluminium heat exchangers featuring super thin walls and minimal use of support structure.

Liquid Cold Plates

PWR has a range of manufacturing options for liquid cold plates used in applications like battery and electronic cooling.
PWR manufacture liquid cooling plates and brazed chassis for Aerospace, Defence and Motorsport markets. These components are used in a variety of end applications such as radar systems, autonomous vehicles, energy storage systems and power electronics cooling applications.

Micro Matrix Heat Exchangers (MMX)

Offering unrivalled performance in compact liquid–liquid cooling PWR has a range of Micro Matrix Heat Exchangers or MMX. MMX heat exchangers are extremely efficient, compact and light weight solutions which are constructed from an array of hollow micro tubes, similar to hypodermic needles, that range in sizes from 0.3mm diameter to 1mm diameter.

Performance Aftermarket Products

PWR are global leaders in the design and manufacture of high-performance aftermarket cooling components to suit all makes and models. We have been supplying the Performance Aftermarket industry with cutting edge cooling components for over 20 years and pride ourselves on working with our customers to develop products that deliver the highest level of performance and quality.

Our Capabilities and Services

Additive Manufacturing / 3D Printing

PWR is leading the thermal management industry with unique additive technology which allows us to manufacture thinner structures requiring less build support to enable more complex heat exchanger and component designs with unmatched performance.

Certifications / Accreditations

AS9100D
NADCAP
ISO 14001:2015
DECS Registered for MIL exports
ITAR Compliant
CAGE: Z0UP4
DUNS: 740065990

Cleanroom and Assembly Services

Four isolated and environmentally controlled clean rooms allow PWR to independently manage complex precision assemblies for some of PWR’s state of the art heat exchanger solutions and assembly processes.

Coatings and Cleaning Processes

PWR deliver a number of “Special Process” surface treatments and coatings as per international standards and specifications. These Special Processes are carried out in a purpose built, automated, and controlled chemical processing facility, enabling consistent, high quality results for products undergoing treatments such as pre aluminium vacuum braze cleaning, type II chromate conversion coating, type III hard anodize coating and electroless nickel coatings.

CNC Machining

PWR has 3,4 and 5 axis CNC machines, including fully automated palletised systems. We have a large programming team across our two production locations allowing for 24 hour around the clock programming to deliver a high level of service to our customers.

CNC Sheetmetal and Stamping

Hosting a significant number of sheet metal fabrication machines, PWR has increased its capabilities and technology investment to be an industry leader in sheet metal manufacturing processes, allowing our products to compete on the world stage.

CT Scanning

Used primarily for research & development and quality assurance, this CT scanner opens-up a multitude of potential for further product development and non-destructive testing at PWR for external partners and research institutions.

Engineering and Design

PWR possesses the capability to provide turn-key cooling system solutions through an integrated engineering and design approach from prototype design, specification and simulation, through manufacture, test verification and volume production.

Low to High Volume Production

Having the ability to engage in projects from first stage prototyping allows PWR to support concepts through to production, to ensure the end product is optimized for performance and mass, whilst adhering to packaging & design constraints.

Modular Assembly

In addition to the production of high-performance cooling systems, PWR have a proven track record in assisting our customers in platform integration. As a vertically integrated company with vast capabilities, PWR can manufacture complete sub-assemblies on behalf of the customer as a value-added process to streamline production at the final assembly plant.

Prototyping and Custom Manufacturing

PWR designs and manufactures prototype and custom heat exchange products for a range of market sectors such as Motorsport, Automotive, Emerging Technologies and Aerospace and Defence.

Quality Control

Weighing approximately 42 tonne, PWR’s largest investment to date in a single piece of test equipment occurred with the purchase of a Yxlon FF85 CT scanner. The CT scanner reconstruction produces a complete 3D representation of a component, based on a large number of 2D X-ray images. Computed Tomography allows PWR to draw conclusions on the external and internal structures without the need to physical dissect and analyse the entire component which would otherwise render it unsuitable for future use.

Research and Development

PWR’s research and development (R&D) capabilities are constantly evolving with application of the latest advanced manufacturing technology and materials science, offering short product realisation lead times through internal capabilities.

Simulation

PWR relies on simulation not only to shorten the time to market of product development but also to improve the thermohydraulic performance of each product design prior to manufacture and real- world validation testing.

Testing and Validation

Whether designed as product development parts or customer specific projects, PWR have the ability to test and measure a range of coolers in our Windtunnel against a series of performance criteria all under one roof, enabling accurate product validation and rapid development times.

Tooling, Jig and Fixture Design and Manufacturing

The tooling and fixtures required to produce our cutting-edge cooling solutions are developed by our experienced design team with a focus on ensuring that critical tolerances can be achieved with a high level of repeatability.

Vacuum Brazing and Heat Treatment

PWR’s Aluminium Vacuum Brazing facilitates light weight heat exchangers and aluminium cold plates to be manufactured with superior structural integrity with the use of high strength alloys.

Welding and Fabrication

PWR Advanced Cooling Technology’s talented fabrication team are experienced in custom manufacture of bespoke aluminium heat exchanger assemblies. Quality orientated, our welders receive product specific training and adhere to multiple welding standards while maintaining quality processes in alignment with AS9100.