Optimizing heat management with digital design tools for thermally conductive polycarbonates
The problem with heat: why it matters
In industries like automotive and electronics, managing heat has always been a challenge. Devices generate heat, and if not dissipated properly, it can lead to reduced performance, shorter lifespan, or even failure. Traditionally, manufacturers have relied on metal heatsinks to manage this heat. While effective, these heatsinks are often heavy and costly. Recognizing this challenge, a new solution was developed.
The breakthrough: A digital approach to heat management
The answer to the problem lies in thermally conductive polycarbonates that offer excellent thermal conductivity while being significantly lighter than metals. However, introducing a new material requires proving to engineers and designers that it can perform as well as, if not better than, existing options. To address this, advanced digital design tools were created.
A high-fidelity simulation approach allows for precise predictions of how these thermally conductive polycarbonate heatsinks will perform in real-world conditions. By using advanced micromechanics, the simulation can account for directional, or anisotropic, thermal conductivity resulting from fiber orientations in molded heatsinks. This detailed modeling ensures that downstream simulations, which rely on computational fluid dynamics (CFD), are accurate and reliable.
Making innovation accessible: The Heatsink Screen Tool
Alongside simulations, we launched the Makrolon® TC Heatsink Screener—a web-based platform based on AI technology that allows engineers to virtually test their heatsink designs using different grades of Makrolon® TC polycarbonates. The tool also enables users to compare their designs to traditional aluminum heatsinks, showcasing the benefits of reduced weight and cost without compromising on performance.
Additionally, the Heatsink Screener offers optimized design configurations. This feature helps even those new to polycarbonate heatsinks quickly understand how to balance thermal performance, weight, and cost, guided by our digital design expertise.
The impact: A new era of design possibilities
These digital tools have already made a significant impact across industries. Automotive lighting manufacturers, for example, have adopted Makrolon® TC polycarbonates as an alternative to metal, taking advantage of lighter, cheaper components that maintain high performance. This switch not only reduces the overall weight of vehicles—critical for improving fuel efficiency—but also aligns with the broader industry push toward sustainability.
Our goal is to provide customers with the highest level of design and material solutions to meet the rigorous technical demands of automotive lighting. Significant weight and cost-saving opportunities are now available through the use of Makrolon® TC thermally conductive.
These developments represent our dedication to providing more sustainable polycarbonate-based solutions, not only in mobility but across diverse markets, including electronics, where heatsinks are used in a range of applications.
