PWR Company CapabilitiesApril 2020

Engineering the Unfair Advantage

PWR Advanced Cooling Technology

Engineering the Unfair Advantage

PWR Advanced Cooling Technology

Discriminators• End-to-end supplier of advanced

cooling solutions from concept, manufacture, validation processes and delivery IFOT

• Design and R&D: PWR has the engineering advantage to find the best solution

• Lead-Time: Manufacturing flexibility reactivity to produce parts in significantly reduced lead times

• Scale: From prototypes to production; testing to validation; Engineering the Unfair Advantage

Engineering the Unfair Advantage

Company Timeline

Engineering the Unfair Advantage

Capability Overview

• CNC 3,4,5-axis machining, EDM, CMM, TIG Welding and CT Scanning

• Complete cooling system design, manufacturing and testing• 3 controlled atmosphere braze furnaces in Australia and US.• Vacuum brazing and Additive Manufacturing in Australia• State of the art wind tunnel calorimeter to develop products and

validate performance of radiators, heat exchangers, charge air coolers and electronic cooling solutions

• Liquid cold plate testing for validation of performance –including experience with water/glycol mixes and synthetic fluids such as PAO

• Engineering groups in Australia and US for customer product development and manufacturing including computational fluid dynamics (CFD)

Engineering the Unfair Advantage

Certifications and CompliancePWR Australia Facility:• ISO9001-2008• ITAR Compliant• DECS Registered for Mil Exports (266498D)• AS9100 (2020)

C&R Racing - USA Facility:• IATF16949• ISO9001-2008• ITAR Registered (M26450)• EAR Compliant

Engineering the Unfair Advantage

Product CategoriesRadiators and Heat Exchangers Including curved and profiled options for charge cooling, oil cooling and LTR (Low-Temperature Radiator)

MMX (Micro-Matrix Heat Exchanger) Technology for Liquid/Liquid and Air/Liquid Cooling

Liquid Cold Plates for power electronics, inverters and battery packs

Metal Additive Manufacturing (3D printing) for driving technology advancement

Engineering the Unfair Advantage

Radiators and Heat Exchangers

• Custom air/liquid heat exchangers based on CAB brazing process – bringing highest level of automotive cooling technology to your cooling needs

• Type of construction depends on fluid type, temperature and pressure

Extruded TubeBest

BetterBest

GoodBetterBest

Rolled TubeBest

BestGood

GoodGoodBetter

Plate and FinGood

BetterGood

BetterBetterGood

Bar and PlateGood

GoodBetter

BestBestGood

High Flow

Low Flow

High Pressure

High Temperature

Durability

Weight

• Using multiple techniques and integrated geometries to maximize performance• Extruded Tube and Fin• Rolled Tube and Fin• Plate and Fin• Bar and Plate• Tube in Shell (MMX)

Engineering the Unfair Advantage

Curved and Profiled Radiators

• PWR has been a leader in the manufacturing of curved and profiled radiators and heat exchangers

• Packaging and compactness is biggest drivers for using these unconventional shapes

• Using multiple techniques and integrated geometries to maximize performance• Motorsports• Aerospace

• VTOL• eVTOL• Hybrids• ICE• Turbine

Engineering the Unfair Advantage

Micro-Matrix Heat Exchangers (MMX)• PWR has dedicated manufacturing for Micro-Matrix Heat Exchangers (MMX). These miniature hollow tube-in-shell heat

exchangers have extraordinary capacity for liquid-liquid and air-liquid applications in a compact volume (200 cm3 capable of >50 kW, 14 lpm, 90oC ETD)

• Designed to maximize surface area and heat rejection• Temperature compatible materials available:

• stainless steel• Peek thermoplastic (250oC)

• Applications:• Battery Cooling• High-Performance and High-Power Computing• Power Electronics (IGBTs, Inverters, Converters,

etc.)• Air cooling• Intercoolers

Engineering the Unfair Advantage

Liquid Cold Plates – Vacuum and CAB Brazed• PWR can bring multiple processes to liquid solutions – Vacuum and CAB brazing

for low profile, embedded compute and high-power heat dissipation• Laminate CAB: Stamped/Laser/Water Jet cut

low-profile cold plates integrated with fin profiles

• Extruded or Billet CAB: pre-formed tubes integrated with machined parts and fin profiles

• Vacuum Brazed: typically machined billet parts integrated with fin profiles

• 6000, 3000 alloys and hybrids possible for each type

• Applications:• Battery Cooling• High-Performance and High-Power

Computing• Power Electronics (IGBTs, Inverters,

Converters, etc.)• Emersion cooling

Large (~1m length) cold plate for autonomous vehicle computing

Battery Pack Cooling System

Prismatic/Pouch Battery Cooling Plate

Cell Battery Cooling Plates

Engineering the Unfair Advantage

Additive Manufacturing

• Initial commissioning and qualifying tools in Australia underway• SLA platform for high temperature and high

strength Somos Perform material• Conventional laser powder bed fusion

aluminium printing• VELO3D partnership for aluminium laser powder

bed fusion:• Non-porous aluminium walls of 0.3mm• Porous structures of 0.2mm• Build angles of 10o off the bed without

support structures, which is an advantage for complex internal structures

• ~100:1 height to diameter build ratio• The impact of AM on HEX builds and

performance will be investigated going forward

Discriminators• End-to-end supplier of advanced cooling solutions from concept, manufacture,

validation processes and delivery IFOT• Global leader in manufacturing bespoke and specialized cooling systems:

PWR supplies 9 of 10 Formula 1 racing teams • Manufacturing flexibility to produce parts in significantly reduced lead times

Capabilities• 3 controlled atmosphere braze furnaces in Australia and US.• State of the art wind tunnel calorimeter to develop

products and validate performance of radiators, heat exchangers, charge air coolers and electronic cooling solutions

• Liquid cold plate testing for validation of performance – including experience with water/glycol mixes and synthetic fluids such as PAO

• Engineering groups in Australia and US for customer product development and manufacturing including computational fluid dynamics (CFD)

Engineering the Unfair Advantage

PWR Advanced Cooling TechnologyCompany and Products • PWR is a public company with over 300 employees globally and 20

years experience in brazed aluminum cooling technology• PWR designs and manufactures all heat exchangers at its

facilities in Australia, USA and UK• PWR manufactures light weight, high durability Turbine,

ICE and Hybrid cooling solutions for UAV, Land Vehicles and Battery Cooling

• Cooling solutions for intercoolers, radiators, heat exchangers and brazed cold plates

• High-capacity air cooling for charge air systems

Key Customers• Defense - Elbit Systems, Reinmetall, Heat Treatment Australia and HDT Global• Motor Sports - F1 Teams including RedBull, Ferrari and McLaren• OEM's - Porsche, Audi, BMW, VW, Ford, Aston Martin and Pagani• Energy Storage - Google X, Renault Sport and Honda

USA Business Contact: Chris Caylor, Business Development Manager, North Americachrisc@pwr.com.au +1 (919) 949-1109 Locations 103 Lahrs Road,

Ormeau QLD 4208+61 (0) 7 5547 1600

6950 Guion Road, Indianapolis, IN 46268+1 (317) 293-4100

Accreditations and CertificationsAustralia Facility:• ISO9001-2008• ITAR Compliant• DECS Registered for Mil Exports• AS9100 (2020)

USA Facility:• IATF16949• ISO9001-2008• ITAR Registered• EAR Compliant

Key Partnerships• Development Partnership: Red Bull Advanced Technologies• Manufacturing Partnerships: VELO 3D - Additive Manufacturing