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Liquid Cooling Cold Plates
Machined or extruded channel plate with an FSW closure, the core architecture.
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Thermal Structures
Liquid cooling assemblies fail where they are joined. LeapFast builds cold plates and heat exchangers as a machined or extruded channel plate with a friction stir welded closure, a hermetic, full-strength joint with no braze foil, no gasket, and no leak path.
Liquid cooling cold platesHeat exchangersEV and battery trays
Primary capability
Friction Stir Welding (FSW)
As power density rises, brazed and gasketed cooling designs run out of room, thermally and in yield. A friction stir closure seals hermetically, survives pressure cycling, and removes an entire furnace step from the build. It also permits channel geometry that a brazed stack-up cannot hold.
The problem
If Any of These Is True, It Is Worth a Conversation.
01Leak-test failures and scrap on brazed or gasketed cold plates
02Thermal performance no longer keeping up with power density
03Recalls or warranty cost tied to a leaking or cracked joint
04Gun-drilled or bonded plate designs limiting channel geometry
05Braze cycle adding a furnace step, fixturing, and lead time
06Weight and joint count from fasteners, tubes, and manifolds
Applications
What We Build for Thermal Structures
02
Heat Exchangers
A brazed-plate replacement with a hermetic, full-strength seal.
03
EV & Battery Trays
Structural, sealed enclosures with integral cooling.
04
Power Electronics Baseplates
Inverter and drive thermal structures at rising power density.
Also relevant here
Beyond the Primary Capability
ALSO
Dissimilar-Metal Joining
Aluminum-to-copper joints that remove bulky mechanical transitions and let the designer pick the right alloy for each side.
ALSO
Leapsight & MetalWorks Digital Twins
Weld parameters modeled and optimized before metal is cut, which shortens qualification.
Why us
What Stands Behind the Claim
- Hermetic Seal
- The strongest single claim in liquid cooling, not reliably achievable with mechanical or brazed joints.
- Fewer Process Steps
- No braze foil, no furnace cycle, no gasket, no post-weld straightening.
- Alloy Freedom
- Alloys that crack under fusion welding are routine for FSW, so alloy choice can follow thermal and structural performance.
Questions
Straight Answers
How Does This Compare With a Brazed Plate?
A friction stir closure is a solid-state joint with parent-metal-class strength and a hermetic seal, produced without a furnace cycle. Brazing adds a thermal cycle, fixturing, and a joint whose integrity depends on wetting.
Can You Match Our Existing Channel Design?
Usually the channel design can stay and only the closure changes, which is the least disruptive way to trial the process. Send a drawing and we will tell you.
What Volume Can You Support?
Development and prototype now, with production scaling through equipment and university partners. Tell us the volume and the date and we will be straight with you about the ramp.
Next step
Send Us the Part That Is Holding Up Your Program.
A drawing, a STEP file, or a sketch and a size is enough. We reply within 3 business days, including when the answer is no.
contact@leapfast.com
(330) 242-6951
252 W Boardman St, Youngstown, OH 44503