Additive Manufacturing (3D Printing)

SenTherm by Senergy Innovations is a family of highly advanced, thermally conductive polymer nanocomposites designed to replace metals like aluminium in components designed to handle thermal loss. 

While excelling in traditional methods like injection moulding, extrusion, and thermoforming, our high-performance base resins (such as Polyethylene, Polypropylene, PA6, PPA, and PPE/PA alloys) make them excellent candidate materials for additive manufacturing (3D printing)—specifically for Fused Granular Fabrication (FGF / pellet printing) and more traditional Fused Deposition Modelling (FDM) with a pre-extruded filament. Applying SenTherm to additive manufacturing unlocks the following geometric and functional use cases:

1. Electric Vehicle (EV) Components & Battery Packs 

Custom Battery Enclosures: Printing lightweight, complex EV battery modules with integrated cooling pathways. SenTherm provides the required structural enclosure while actively dissipating heat away from the cells.
Power Electronics Housings: 3D printing custom-shaped heat-dissipating jackets or brackets for invertors and converters. 

2. Complex Heat Exchangers & Heat Sinks

Conformal Cooling Channels: Additive manufacturing can print internal, curved lattice structures and complex fluid channels that injection moulding cannot replicate. Printing SenTherm directly creates optimised static or dynamic heat exchangers.
Bespoke Heat Sinks: Tailor-made, lightweight fins for electronic cooling system prototypes without the high cost of metal machining or custom molds.

3. Energy Systems & Solar Thermal Elements

Custom Solar Collectors: Prototypes for SenTherm’s  original product—efficient solar thermal energy conduction—to 3D print bespoke solar heat absorber geometries or specialized manifold connections on-demand.
Geothermal Components: Building low-temperature thermal management elements that resist corrosion better than metals while keeping high thermal transfer rates. 

4. Automotive Thermal Management

Non-Structural Metal Replacement: AM / 3D printing lightweight prototype components (such as coolant fluid connectors, ducting, and brackets) to replace bulky, heavy metal equivalents.
Under-the-Hood Housings: Utilizing high-temperature formulations (like SenTherm PPA grades capable of handling up to 150°C) to print components positioned close to vehicle engines or powertrains. 

5. High-Power LED Lighting Fixtures

Integrated Casings: Printing architectural or performance automotive LED housings where the structural body acts directly as the thermal heat sink, lowering the bill of materials and avoiding overheating.

Technical Advantages of AM / 3D Print with SenTherm

Lightweighting: Parts closely match the thermal performance of aluminum and  feature a dramatically reduced polymer-based weight.
Design Freedom: Eliminates standard tooling restrictions, allowing engineers to design topology-optimized thermal parts.
Low Carbon Prototyping: Allows rapid testing of zero-emission thermal devices without wasting block metal scrap via subtractive milling.