Explore Thermal Management Solutions for the eVTOL Industry

As electronics in the electric vehicle takeoff and landing (eVTOL) industry become more compact and powerful, efficient thermal management is crucial to ensure performance, safety, and reliability. High-density battery systems and advanced electronics generate significant heat; which, if not managed properly, can lead to inefficiencies and reduced lifespan of critical components. Senior Metal Bellows (SMB) specializes in custom-engineered bellows and sealing solutions that support advanced thermal management systems, helping optimize efficiency and ensuring the long-term durability of eVTOL technology in demanding environments.

Reservoir for eVTOL Battery Cooling System

Our customer required a maintenance-free reservoir to manage large volume changes in their water battery cooling system for an electric aircraft. As a critical part of the cooling system, the reservoir needed to be highly reliable and designed to last the life of the aircraft.

Senior Metal Bellows’ all-welded titanium bellows reservoir provided a lightweight, durable solution that fit within a tight installation window. The customer brought a challenging, technical issue to SMB’s engineering team and left with a solution that is both cost-effective and technically robust.

Volume Compensator for eVTOL Propulsion Electronics Cooling System

Our customer developed an eVTOL aircraft with an advanced liquid cooling loop for the electric propulsion system, which required robust cooling solutions to prevent damage from the massive waste heat generated by the electronics, batteries, and propulsion equipment that could lead to failures.

SMB designed a maintenance-free, lightweight titanium bellows volume compensator that integrates directly into the propulsion system, maintaining proper fluid pressure while managing the thermal expansion of the coolant fluid.

Volume Compensator for eVTOL Cooling System Power Supply

Our customer required a lightweight volume compensator to accommodate the thermal expansion of coolant fluid in the primary electronics cooling system for an eVTOL aircraft’s power supply.

Problem

Assembly needed to endure the shock loads and flight conditions of the aircraft.
Assembly had to support the weight of the fluid without moving or negatively impacting performance and system pressures.
Assembly was required to compensate for thermally induced volume changes with minimal pressure increase, all within a confined space.

Solution

Senior Metal Bellows delivered a fully titanium welded metal bellows featuring specialized vibration dampening, resulting in a maintenance-free volume compensator that offers:

Extremely low weight and compact installation
Minimal pressure fluctuations while ensuring steady fluid flow
Reduced life cycle costs
Zero leakage due to a hermetically sealed bellows design
Reliable performance across a wide temperature range.