Advanced Thermal Systems
Manufacturing Support
Prototyping & Production
MANUFACTURING SUPPORT
From Process Development to Production
Thermal Design Solutions collaborates with specialised manufacturing and testing partners to transform concepts into validated heat exchanger designs and then to production. Our manufacturing support services cover process definition, tooling design, prototyping, small series manufacturing, and production troubleshooting.
With over 50 years of combined manufacturing experience through our partner network, we ensure every design is manufacturable, durable, and cost-effective.
Get In TouchPROCESS DEVELOPMENT
Manufacturing Process Development
We define and optimise manufacturing processes for heat exchangers and related thermal system components, balancing product performance, durability, and cost targets. Capabilities include:
- Precise aluminium cutting, drilling, turning, and stamping on eccentric and hydraulic presses.
- Heat treatment processes adapted for thermal system alloys.
- Surface finishing including vibro-abrasive, rotary abrasive, and spray-wash treatments.
TOOLING
Tooling Design & Construction
We design and oversee the production of custom tooling to ensure precision and repeatability in manufacturing.
- Tooling for extrusion, forming, and bending of tubes and fins.
- Press tools for aluminium stamping and component forming.
- Brazing fixtures for accurate component assembly and joint integrity.
PROTOTYPING
Rapid Prototyping
Rapid prototype production enables early validation of design concepts before committing to tooling.
- Single units or small batch prototypes.
- Built to final production geometry and materials.
- Tested for thermal performance, durability, and system integration.
PRODUCTION
Series & Small Series Production
Our partners are equipped for both low-volume specialty builds and full production runs, including:
- CAB Nocolok brazing (protective atmosphere, very low flux residue).
- Assembly lines for multi-HEX modules.
- Quality control processes in line with automotive OEM requirements.
Our partner’s founder brings over 50 years’ experience in automotive heat-exchanger manufacturing, with CAB Nocolok brazing and very low flux residue processes for joint integrity.
PROBLEM SOLVING
Problem Solving & Troubleshooting
We resolve production-line issues and post-production failures through root cause analysis and corrective design or process changes.
- Durability issues (corrosion, thermal cycling, vibration).
- Brazing defects and leak testing failures.
- Process variability impacting performance or cost.
TESTING
OEM-Certified Testing Capabilities
Through our partners, TDS offers comprehensive validation testing for thermal systems, batteries, and automotive components:
- Material testing — chemical composition, coatings, VOC, emissions.
- Component & assembly testing — durability and performance validation for HEX, batteries, gearboxes, chassis components, and more.
- Environmental durability — acoustic (NVH), vibration, pressure cycling, thermal shock, corrosion, and ageing resistance.
- Electromobility testing — EV battery range, performance, and safety validation.
- Burst pressure testing and helium tightness verification — for leak-free reliability.
These facilities are certified by major OEMs, ensuring results are accepted across the automotive industry.
YOUR ADVANTAGE
Your Manufacturing Advantage with TDS
- Direct link between design, simulation, and manufacturability.
- Access to advanced machining, brazing, and finishing technologies.
- Rapid prototyping validated under OEM-certified test regimes.
- Proven success in bringing first-of-their-kind thermal products to market.
Our Services