Switzer

Aerospace environments penalize excess mass. Launch vehicles require extreme thermal control under severe conditions. Traditional shell-and-tube heat exchangers are too heavy and voluminous. Printed Circuit Heat Exchangers (PCHEs) solve these structural problems.

A PCHE consists of chemically etched metal plates. These plates are diffusion-bonded into a solid metal block, which behaves like a single piece of metal. This construction gives PCHEs massive advantages over older heat exchanger designs:

-They offer much higher surface area per unit volume.
-They reduce total component mass significantly.
-They tolerate extreme internal pressures.

These traits are vital when designing space propulsion systems. Every ounce saved increases payload capacity, and every inch of space saved allows for better component layout.

Learn more about how PCHEs built via PCM deliver aerospace performance within a compact envelope in our latest article: https://www.switzermfg.com/blog/why-pches-matter-in-launch-and-propulsion-systems/

Today is the day!

You can find us at Booth 851 at Space Tech Expo 2026, where we'll be showcasing photochemical-machined thermal management components that meet the extreme environmental demands of the aerospace industry.

Looking for a more personalized discussion of your exact needs? You can book a consultation with one of our thermal management specialists before you even hit the show floor:
https://pulse.ly/s4paqzmktn

Extreme vibration, shock loads, rapid temperature changes, pressure fluctuations, and very long operating times create demanding conditions for aerospace heat exchangers. The challenges presented by the aerospace environment increase the difficulty of material selection and fabrication of the microchannel heat exchangers (MCHEs).

The best performance of MCHEs in aerospace and defense applications typically results from using an alloy that can be formulated for the expected service conditions and using a fabrication method that produces fine features without damaging the aluminum.

In our latest article, we'll break down the trade-offs involved in the choice of material for aerospace-grade MCHEs, and the manufacturing considerations that play a major role in whether an aerospace-grade MCHE performs as intended.

Read More: https://pulse.ly/ronquhkkki

The most effective flow field plates are not just optimized for performance - they are designed from the start to be manufacturable at scale. Many manufacturing programs fail because they separate plate design from the rest of the fuel cell or electrolyzer system.

Common pitfalls in the design and production of flow field plates include:
-Designing features that exceed the aspect ratio limits of etching
-Requesting tolerances that the process cannot repeatedly meet
-Ignoring the impact of coatings on final dimensions
-Involving the manufacturing team only after the design is “locked”

Read more about bringing plate engineers and stack designers together early to balance cost, yield, and efficiency in our latest article: https://pulse.ly/iwnv2le25s

Space Tech Expo 2026 is fast approaching on June 3-4 in Anaheim, CA!

With over 70 expert speakers from across the space supply chain, this is your opportunity to dive into key industry trends, explore new opportunities, and attend high-impact sessions.

Be sure to join Switzer at Booth 851 as we discuss the challenges of thermal management performance in extreme environments, and the role that PCM etched components can play in ensuring system reliability and safety.

Register for the conference here: https://pulse.ly/rwzp9ej8ho

MARKET SPOTLIGHT: Hydrogen Technology

Component design can have an outsized impact on the performance of specific hydrogen generation and electrolysis products. Our PCM technology offers custom channel design options not achievable through traditional manufacturing methods, such as stamping and hydroforming. These advanced design options help deliver outstanding electrical conductivity, heat transfer, optimized catalytic performance, and enhanced output and efficiency

Our manufacturing expertise includes a range of products specific to hydrogen technology:

-Bipolar Plates
-Flow Field Plates
-Support Screens & Custom Spacers

Learn more about our extensive experience manufacturing components for hydrogen generation and electrolysis applications: https://pulse.ly/2odjagvz1b

Designing a high-performance fuel cell or electrolyzer stack is a massive balancing act, with the flow field plate functioning as the lungs and nervous system of the stack. When plate engineers and stack designers work in separate silos, the project usually hits a wall. You might end up with a brilliant theoretical design that is physically impossible to manufacture at a reasonable price.

True efficiency happens when these teams sit down together during the earliest stages of prototyping. In our latest article, we'll break down 7 key design considerations in flow field plate performance as well as common pitfalls to avoid in a hydrogen technology manufacturing program.

Read More: https://pulse.ly/yzzjfapidz

MARKET SPOTLIGHT: Hydrogen Technology

Hydrogen technology is becoming increasingly vital in the global transition to sustainable energy. As the demand for cleaner fuel solutions grows, the need for reliable, efficient hydrogen generation and electrolysis is becoming more crucial.

At Switzer, we understand the challenges of advancing in a developing field, and the need to combine innovation with efficiency. Our flow field, cooling and bipolar plates offer customization options unmatched with other manufacturing methods, empowering rapid, low-cost prototyping and collaboration.

As your precision component manufacturing partner, we understand the unique demands and requirements of the Hydrogen Technology market, including:

-Custom channel design capabilities for flow field and bipolar plates.
-Thicker metal plate capabilities for improved stability.
-Flexible channel configuration for optimal land areas and less clogging.
-Full stack provider (except membranes and converters).
-Rapid prototyping and low-cost tooling.
-Stainless steel to resist corrosion.
-Compliance with regulatory standards across regions and industries.

Learn more about our range of solutions specific to the Hydrogen Technology industry here: https://pulse.ly/ygrod3qinf

Building an effective microchannel heat exchanger (MCHE) requires extreme precision. The geometry of the channels dictates the performance of the entire system, so traditional manufacturing methods like stamping or laser cutting often fall short.

Photochemical machining (PCM) is a different approach. It uses a chemical etching process to remove metal and does not introduce mechanical stress or heat into the part. This ensures the internal flow paths remain clean and smooth.

Benefits of Photochemical Machining for manufacturing MCHEs:
-Allows for high-density channel features that other fabrication methods cannot replicate.
-Can produce complex, multi-layered designs - including variable channel depths and intricate manifolds.
-Works exceptionally well with thin-gauge materials.
-Thinner MCHE plates allow for faster thermal response and lighter total weight.

Read more about the relationship between fluid dynamics and metal fabrication in manufacturing MCHEs in our latest article: https://pulse.ly/fst7yvmeww

TRADE SHOWS & CONFERENCES - Space Tech Expo 2026

Space Tech Expo is moving to Anaheim, CA for 2026 and bringing together over 350 companies in the space supply chain offering cutting-edge solutions, including electronics, materials, testing, components, and more.

Attendees can take advantage of two dynamic stages at this free-to-attend conference: Industry, which focuses on the biggest industry trends and market obstacles, and Technology, which focuses on engineer and advancing essential capabilities.

In addition, the Skills Lab (new for 2026) offers workshops and masterclasses to inspire and empower attendees.

You can find Switzer at the Space Tech Expo 2026 at Booth 851.

Register for the conference here: https://pulse.ly/lzmay1epx8