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Reliefed
’ s forming technology producing complex geometries in one continuous step.
Fast, metal-free flow plates: A breakthrough in heat exchanger manufacturing
A patented method from Reliefed is changing the game for heat exchanger plate production- enabling rapid, cost-efficient manufacturing using composites, ceramics, and polymers instead of metal. The result: lighter, corrosion-resistant, and more sustainable thermal systems.
Text & images by Reliefed
Swedish manufacturing innovation company Reliefed has developed and patented a manufacturing method that redefines how non-metallic flow plates can be produced for heat exchangers and thermal systems. By upgrading the conventional extrusion process with inline precision forming, the company can manufacture fully structured flow plates with complex geometries in a single continuous step, reaching production speeds of seconds per plate. This removes the design and scalability barriers that have previously limited the use of composites, ceramics, and polymers in flow plates. The result is a highly efficient production method that opens new material possibilities, reduces manufacturing costs, and supports the industry’ s shift toward lower carbon, corrosion and fouling resistant solutions.
Moving beyond metal Many heat exchanger systems continue to rely on stainless steel, titanium, or nickel-based alloys for plate production. While these materials are mechanically robust, they are often used as a safeguard rather than a precise match for the operating conditions in large part due to the limited availability of alternatives that meet both performance and production requirements. In addition they contribute to higher material costs, energy usage, and high environmental impact. Non-metallic materials offer benefits such as improved corrosion resistance, reduced fouling, and lower weight. Until now, their use has been limited by slow and expensive manufacturing processes. For example, compression molding, injection molding or extrusion and machining of heat exchanger plates typically have a cycle time of several minutes per plate. Reliefed’ s method can energy efficiently produce a fully structured plate in a matter of seconds reducing cycle times and cost of production.
A new approach to extrusion The patented forming process developed by Reliefed, retrofits directly onto existing extrusion lines. Using custom tooling and a rotating shaping element, the method continuously forms flow channels into extrudable materials. This enables single-step production of three-dimensional plate geometries without additional machining, pressing, or secondary handling. The process is material agnostic and has been validated for use with a range of materials; composites, technical ceramics and polymers. The
26 Heat Exchanger World July 2025 www. heat-exchanger-world. com