Case Study
Developing a Fanless Cooling System for Small Cell Radios in Telecommuncations
T he project focused on developing a cooling system for small cell radios that did not require additional fans. Traditional fan-based solutions were noisy and posed a maintenance challenge, especially when they failed during peak demand, affecting network quality of service (QoS). The goal was to create a cooling system that reduced maintenance costs, improved network reliability, and was suitable for low-volume production while ensuring compliance with Telcordia standards.
T he project faced technical difficulties in predicting the amount of cooling required, which varied based on the radios’ orientation, operating parameters, and environmental conditions. Material selection was challenging, as the materials needed to withstand high temperatures while being cost-effective. Compliance with Telcordia standards added complexity, requiring careful management of thermal and solar loading without obstructing radio signals or increasing heat gain. Although complex shapes and ducting could theoretically solve the cooling problem, these designs needed to be quickly and cost-effectively produced, harmonizing with the existing skills and tools of the workforce.
T he team collaborated with suppliers to spec bulk materials that met aesthetic and thermal requirements for external use. Internally, they selected high-performance 3D-printed materials to create the complex ducting needed for effective cooling. As production volumes grew, they developed tooling methods for cast urethanes to enhance cost-effectiveness. Computer simulations and laboratory validations were closely aligned, with results agreeing within 10%, showcasing the accuracy of the analyses.
Case studies
How We've Helped Clients
Enhancing Manufacturing Safety and Reducing Costs in Automotive Manufacturing
In an automotive manufacturing plant, the manual intervention required during an upsetting operation for a front-wheel-drive
Accelerating Fighter Plane Development in the Competitive Aerospace Environment
A client in the aerospace industry was engaged in the development of a new fighter plane for a foreign power.
Transforming Aircraft Modification and Certification Processes to Restore FAA Trust
A helicopter aftermarket OEM faced significant challenges related to FAA Continuous Operational Safety (COS) items tied to its supplemental type certificates
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