Research and Development

PWR’s research and development (R&D) capabilities are constantly evolving with the times. With global markets and customer requirements forever changing, and ongoing advancements in technology and materials science, PWR continue to diversify their skills and R&D capabilities across a range of key areas.

Although PWR’s global success grew rapidly from within the motorsport industry, in today’s climate, PWR offers a larger selection of cooler types and R&D services to a broader market, including several emerging industries. Previously, PWR specialised in the production of aluminium-only heat exchangers which saw competencies focused around more traditional activities such as metal fabrication, assembly, brazing, welding, and performance testing. Whilst maintaining these core competencies, ongoing investment into R&D has seen PWR’s skill set and capabilities grow significantly.

PWR now manufactures coolers in a variety of shapes and sizes and from a mixture of materials in addition to aluminium. Extensive R&D programs have led to the development of specific processes and techniques for assembling irregularly shaped coolers, joining dissimilar materials, precision machining, heat treatment, and various chemical and mechanical surface treatments. Coupled with in-house Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and Wind Tunnel validation, PWR has positioned themselves to offer well-balanced, full-service R&D solutions.

Adding further weight to PWR’s R&D capabilities is a 32-tonne industrial size Computed Tomography (CT) scanner. The Yxlon FF85 CT scanner has an inspection envelope of 1000mm height x 850mm diameter, allowing parts as big as 2000mm height x 1500mm diameter to be interrogated with full 360° rotation. Having up to 450 kV electrical potential, 320 W of tube power and with a focal spot size of less than 6µm, this instrument gives PWR full insight into weld penetration, inclusions and porosity, braze quality, internal product features and geometry that would otherwise be unknown without destruction. Used primarily for R&D and quality assurance, this CT scanner opens-up a multitude of potential for product development and non-destructive testing at PWR and for external partners and research institutions alike.

Extending PWR’s R&D and manufacturing potential even further, is the new additive manufacturing department. This currently includes two 3D metal printers and an SLA printer an array of FDM printers for prototyping and small batch production. To learn more please visit our Additive Manufacturing capabilities.

Bolstering PWR’s capabilities further includes the addition of a dedicated vacuum brazing division, dedicated heat treatment facility and automated anodising and chemical conversion line.

PWR works closely with their customers from initial concept development, through to prototyping, testing, and final production. Having a vast portfolio of R&D tools and specialists make PWR an ideal partner to research and develop your cooling needs.