Speakers:
Antonio Di Caterino, Customer Success Lead, ToffeeX
Daniel Mak, Engineer, Advanced Materials and Processing Laboratory, Nissan Motor Co., Ltd.
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Optimization of a Cross-Flow Oil Cooler with Generative Design
20.11.2025
In this session, we present the collaborative development of a cross-flow oil cooler for Nissan, leveraging the latest advances in generative design tailored for thermal-fluid optimization. The goal: maximize heat transfer while minimizing pressure drop—within strict manufacturing constraints for additive production. Using the latest two-fluid optimization tools, we explored a range of novel heat exchanger designs, achieving a solution that outperformed conventional gyroid and plated alternatives by over 6x in heat transfer-to-pressure drop efficiency. We’ll share how we navigated constraints such as minimum wall thickness, 45° SLM overhangs, and manufacturability, culminating in the successful 3D print of a complex, self-supporting geometry. This case study illustrates how generative design and additive manufacturing can radically improve thermal performance in compact automotive systems—and opens new pathways for high-efficiency, production-ready heat exchangers.