AmPro Innovations: Redefining the Future of Heat Sinks through Metal 3D Printing — From Prototype to Mass Production

In recent years, as industries such as consumer electronics, 5G communications, new energy vehicles, and aerospace have raised the bar for thermal management, traditional heat sink manufacturing processes have increasingly revealed their limitations. Confronted with challenges such as the difficulty of fabricating complex microstructures, the need for high assembly precision, and material constraints, Suzhou AmPro Innovations Technology Co., Ltd. (hereafter “AmPro Innovations”) has leveraged metal 3D printing technology to revolutionize the design, performance, and scalability of heat sinks.

As one of China’s representative enterprises in metal additive manufacturing, AmPro Innovations has established a fully integrated industrial chain covering materials, processes, and equipment. Through its deep expertise in thermal management, the company has successfully advanced 3D-printed heat sinks from conceptual prototyping to industrial-scale production.

About AmPro Innovations
Founded in August 2017 by Dr. Wu Xinhua, a leading expert in titanium alloys and additive manufacturing and a fellow of the Australian Academy of Technological Sciences and Engineering, AmPro Innovations is based in Suzhou High-tech Zone, Jiangsu Province, within the Yangshan Smart Industrial Park. The company specializes in providing end-to-end industrial metal 3D printing solutions, encompassing metal powder R&D and production, printers ranging from small to extra-large scales, process optimization, post-processing systems, and component manufacturing services.

From Conventional Manufacturing to 3D Printing: An Inevitable Technological Evolution

Traditional manufacturing of vapor chamber (VC) and microchannel liquid-cooling heat sinks involves complex, multi-step processes plagued by several inherent challenges:

1. Difficult Capillary Fabrication: Maintaining uniform pore size and layer thickness in sintered structures is challenging, often leading to clogging or uneven reflux.

2. Brazing Defects: Uneven bonding surfaces and internal contaminants frequently result in weak joints or deformation.

3. Microchannel Limitations: Conventional 2D processes cannot produce intricate 3D geometries, and issues like welding deformation and sealing risks remain unresolved.

These constraints have long hindered innovation in both heat sink design freedom and performance optimization. The introduction of Selective Laser Melting (SLM) technology has fundamentally changed this landscape. By enabling one-step fabrication of complex capillary channels, heterogeneous porous structures, and integrated flow housings, AmPro Innovations has minimized assembly stages and eliminated the leakage risks associated with traditional joining methods.

Four Key Advantages of Beifeng’s 3D-Printed Heat Sinks

1. Design Freedom and Monolithic Construction
3D printing allows for the direct creation of intricate capillary geometries such as honeycomb, porous, and dendritic structures, integrated seamlessly with shells, supports, and flow channels. This one-piece design eliminates alignment errors and weak solder joints, vastly improving reliability — particularly valuable for compact, high-density devices like laptops and 5G modules requiring tailored cooling solutions.

2. Material Advancements for Extreme Environments
Whereas traditional VC heat sinks are almost exclusively copper-based, Beifeng’s process extends to titanium, aluminum, stainless steel, and Inconel superalloys. Its proprietary GA520 high-strength aluminum alloy offers exceptional yield strength and elongation while supporting anodic oxidation treatment. As a result, Beifeng’s 3D-printed heat sinks can operate reliably in high-temperature, corrosive, and vibrational environments, unlocking new potential for aerospace and defense applications.

3. Process Optimization for Peak Performance
Through advanced densification control, Beifeng has reduced porosity to below 0.3%, achieving a near-theoretical density of 99.7%, well above industry standards. Surface roughness has been improved to 0.6 μm externally and as low as 2.2 μm internally, delivering mirror-like smoothness that enhances fluid flow and thermal exchange efficiency.

In addition, residual stress management and optimized support structures prevent warping in thin-walled geometries. The company’s heat sinks feature wall thicknesses as fine as 0.3 mm and flow channel widths of just 0.143 mm, far surpassing conventional machining capabilities.

4. Rapid Iteration and Scalable Production
The “from CAD to reality” model of 3D printing dramatically shortens R&D cycles, allowing custom VC structures tailored for high-heat-flux chips. With a production workshop housing over 100 metal printers, AmPro Innovations has realized the full transition from prototype to mass manufacturing, meeting both customized low-volume and large-scale industrial demands.

Comprehensive Validation: From Airtightness to Flow Performance
Given their critical role in thermal systems, Beifeng’s 3D-printed heat sinks undergo rigorous testing:

· Airtightness Tests: Both positive-pressure (0.2 MPa, 60-second hold) and negative-pressure evaluations show zero leakage, with helium tests confirming complete seal integrity.

· Evaporation Tests: Under 65°C endurance testing, no swelling or mass loss was detected, proving long-term stability.

· Flow Tests: Capillary water injection trials demonstrated smooth circulation with no leakage or backflow.

These results collectively confirm that Beifeng’s 3D-printed heat sinks match — and in many cases surpass — the reliability and performance of conventionally manufactured ones.

Applications: From Aerospace to Rocket Engines

Beifeng’s 3D-printed heat sinks have already proven their capabilities in a range of high-end applications. In one notable aerospace case, a GA520 aluminum alloy thermal oil cooler was produced in just 36 hours, showcasing the company’s blend of efficiency and performance. Beifeng continues to expand its footprint across aerospace, electronics, and new energy sectors.

Conclusion: 3D Printing Is Reshaping the Future of Thermal Management
AmPro Innovations’s innovations illustrate that 3D-printed heat sinks are far more than a process substitution — they represent a comprehensive industrial transformation. By overcoming the limitations of conventional manufacturing, 3D printing delivers breakthroughs in design freedom, material versatility, process precision, and production efficiency.

As the demands of 5G, AI, high-performance computing, and aerospace continue to grow, metal 3D-printed heat sinks stand poised to become the cornerstone of next-generation thermal management. With its integrated industrial chain and deep technical foundation, AmPro Innovations is set to play a defining role in this emerging frontier.