Innovation continues to push the boundaries of power density and efficiency in aerospace and defense electronic systems. With more power comes more heat, and packaging these power-hungry components within a SWaP-constrained infrastructure leads to formidable thermal challenges.

In these systems, where every pound and foot can impact performance, a compact, efficient thermal solution is essential for cooling high heat flux systems in extreme temperatures and the most rugged defense environments.

Advanced Cooling Technologies (ACT), a formidable force with over two decades in the thermal management sector, offers rugged, system-level thermal management solutions that effectively cool defense and industrial equipment to achieve maximum operational efficiency. Its solutions have undergone meticulous testing and qualification to guarantee their ability to reliably operate in harsh environmental conditions.
“With ACT as your full system-level thermal management provider, customers benefit from a compact solution, utilizing innovative technologies without adding unnecessary complexity to the overall thermal architecture,” says Pete Dussinger, Chief Engineer, Product Development at Advanced Cooling Technologies.

Optimizing System Performance with Simplicity

ACT offers a comprehensive range of thermal solutions, spanning passive and active cooling systems, both above and below ambient systems. This versatility allows for tailored solutions that bolster system performance across diverse industry applications.

In missile programs, distinct mission requirements often necessitate effective heat management for high heat flux electronics. For example, ACT has engineered passive PCM heat sinks for missile applications. During flight, the heat sink absorbs thermal energy and maintains a stable temperature at the electronics interface while remaining in the melt phase of the solid-to-liquid transition. The design allows for a compact and straightforward solution that ensures essential cooling for these applications.

To reinforce its offerings and cater to an expansive set of client needs, ACT has acquired and introduced the Tekgard® brand’s active cooling solutions into its portfolio. The vapor compression system, a multi-kilowatt cooling device, is a highlight of this acquisition and instrumental for weapon systems and other military applications. These cooling systems are designed to operate across extreme temperature ranges, from frigid -40°F conditions to scorching 130°F environments, and seamlessly adapt to quick changes in thermal power load.

For example, large-scale radar systems for military surveillance use phased-array radars that rely on heat pipes to disperse heat and keep power amplifiers cool. In these systems, ACT also plays a role in managing the liquid cooling loop, ensuring the heat is efficiently transported and expelled from within the system. It integrates vapor compression-based chillers to provide sub-ambient cooling for the liquid, optimizing the cooling process.

ACT also offers HVAC units that cool military personnel and their electronics equipment in shelters, both permanent and mobile.

“We effectively tailor sub-system level solutions for diverse applications by analyzing the entire thermal architecture as one,” says Bryan Muzyka, Vice President of Sales and Marketing at Advanced Cooling Technologies.

Reinforcing Durability Through Engineering Excellence

Adhering to a structured design cycle, ACT sets the stage for excellence in custom-designed thermal solutions. It commences each project by understanding the design intricacies, including the defense, military and industrial standards the solution needs to meet and its environmental requirements. It transitions to the preliminary design phase and a critical design review before moving to manufacturing readiness.

Engineering tools like SOLIDWORKS and ANSYS ensure precision and excellence during these stages. Before manufacturing, materials are carefully selected to withstand shock, vibration, corrosion, and similar conditions.

The process then transitions to manufacturing and testing, with in-house facilities adhering to stringent standards like ISO 9001 and AS9100 for aerospace applications, guaranteeing rugged and reliable quality. The robust testing regimen includes in-house and client facility testing during product development and acceptance-level testing in routine production runs.

Embracing a holistic service model, ACT offers on-site installations, servicing, repairs and replacement units. Top-tier client service includes maintaining transparency by seeking client approval at each milestone. Post-project satisfaction surveys are conducted, with client feedback integral to shaping next-generation products. It has consistently surpassed a net promoter score of 90 percent.

ACT’s client-centric mission is illustrated by a requalification process it undertook for its Tekgard brand C57 Chiller. Six years after its initial release, ACT was awarded a contract to produce numerous units to replace chillers from another supplier. However, production was halted after field experience revealed design inadequacies impacting ruggedness and reliability in demanding conditions. The team embarked on a significant redesign and requalification effort to rectify these shortcomings. After subjecting the equipment to shaker table testing, they identified multiple issues, including fasteners vibrating loose, refrigeration lines cracking, and condenser coil mounting flange failures. They developed remedial measures, validated them through rigorous testing, and complemented them with comprehensive personnel training. Today, the Tekgard brand C57 Chiller stands as a symbol of highly reliable service in the most demanding battlefield conditions.

Spearheading Innovation Through Extensive Collaboration

ACT’s success journey finds its roots in a deeply embedded culture of innovation, an exceptional team that excels in collaboration, and a mission to uphold top-notch customer care.

Innovation is the cornerstone of ACT’s ethos, propelling its staff to consistently challenge the boundaries of engineering and craft unparalleled solutions for the market. A collective approach drives every project, harnessing the combined expertise, innovation and collaborative effort of all team members to provide distinctive solutions. Staff members immerse themselves in the client’s needs and work closely with them at every project juncture to create impactful thermal management solutions.

We Effectively Tailor Sub-System Level Solutions For Diverse Applications By Analyzing The Entire Thermal Architecture As One

The organizational culture is deeply ingrained with these principles. The R&D team focuses on developing robust technology for every readiness level for the Department of Defense, NASA, and the Department of Energy. The product development team customizes this innovative technology to meet specific customer needs. After establishing a stable design, the production team takes the reins, optimizing processes, reducing costs, and elevating manufacturing quality and consistency.

Staying attuned to customer needs, ACT recognizes that its vapor compression solutions come with complexities that make it difficult to maintain. One example is the logistical challenges and high cost of fuel deliveries to military sites with generator-powered environmental control units. As such, ACT is developing a hybrid system combining pumped two-phase technology with vapor compression that can adapt to various environmental conditions with energy (fuel savings) as the driving motivation.

During cooler periods or at night, the ECU conserves energy by using pumped two-phase or passive cooling. When temperatures rise, it switches to vapor compression or active cooling. This game-changing offering is set to join ACT’s portfolio within the year, promising reduced energy consumption and lower generator fuel costs, delivering long-term value to military operations.

ACT continues to be at the vanguard of innovation, changing how defense, medical, energy and other industries approach thermal management solutions. Organizations seeking comprehensive, system-level thermal solutions in a simple package can confidently turn to ACT to unlock peak operational efficiency and prolonged equipment life.