8 Myths About Thermal Design
Today’s thermal design engineers wear many hats, acting as much as project managers as they do design engineers. When managing complex projects, it’s no surprise that thermal issues often take the backseat.
Yet, thermal roadblocks are pretty common during the final stages of a product’s design. Nearly 1 in 5 electronics engineers identify thermal issues as a leading cause of project delays.
Expedited or retrofit solutions exist, but not without steep added costs. Don’t fall victim to cumbersome project lags or expenses by believing these myths about thermal design. We’re debunking 8 common misconceptions — and sharing the truths — related to thermal design.
8 Common Misconceptions of Thermal Design
Myth #1: Thermal Management Isn’t That Important.
Truth: Thermal management is what keeps complex systems operating safely and efficiently throughout the product’s lifecycle.
Powered devices are getting more powerful and more compact across industries. More power means more waste heat to manage. As product footprints decrease, thermal designers are facing a growing challenge: creating solutions that can operate across smaller devices.
Thermal engineers must balance the need to manage increasing device power loads over less surface area. If anything, thermal management is more important now than ever.
Myth #2: Thermal Design Is All About Keeping Electronics Cool.
Truth: Thermal design encompasses everything from device cooling and heating to cycling.
Keeping powered devices cool is a critical piece of thermal design, but it’s broader than just cooling. On a larger scale, thermal design is about developing a system to keep your device at its optimal operating temperature.
In many cases, managing the waste heat is the best thermal solution. But in applications where the system’s ambient temperature is extremely low, heating may be required instead. The type of management your device needs will depend on its requirements and product specifications.
Myth #3: Thermal Design Solutions Haven’t Evolved.
Truth: Thermal design must evolve as high-power electronics do too.
As devices have evolved, thermal design has done the same to ensure these advanced systems can effectively manage increasing heat loads. The list of technologies, components, and materials is vast:
| Technologies | Components | Materials |
|---|---|---|
| • Air Cooling • Liquid Cooling • Two-Phase Cooling | • Heat Sinks • Heat Pipes • Cold Plates • Pumps • Compressors • Condensers | • Aluminum • Copper • Diamond • Water • Ethylene Glycol • Refrigerants |
With all of these options, it can be difficult to determine which is best for your needs, especially if there’s no direct line to a thermal expert who can help.
At ACT, we’re not just keeping up with the evolution of high-power electronics—we’re driving it. Our R&D team is continuously developing cutting-edge thermal management technologies to address the challenges of tomorrow. From advanced two-phase cooling systems to next-generation materials with superior thermal conductivity, we’re committed to pushing the limits of performance, efficiency, and reliability. Whether it’s improving SWaP-C (Size, Weight, Power, and Cost) for rugged electronics or enabling sustainable cooling solutions, our relentless pursuit of innovation ensures that your systems stay ahead of the curve.
ACT’s thermal engineers specialize in a complete range of services, from the initial product conception to design and installation. As a leading manufacturer of thermal management solutions across industries, our team is knowledgeable and committed to helping solve your unique thermal needs.
Myth #4: I Can Deal With Thermal Design Considerations Later In The Design Process.
Truth: Addressing thermal problems head-on helps protect product timelines and reduces failures.
One of the most harmful myths about thermal design is that it can be addressed in the later phases of the design cycle. In reality, thermal evaluations should be conducted during each design phase.
Routine evaluations can help thermal engineers detect any issues that could lead to device failures later on, eliminating costs related to extensive teardowns or other setbacks.
Myth #5: I Can Just Buy A Cheap Heat Sink or Fan Online.
Truth: Complex problems require complex solutions.
Neglecting thermal management best practices during the product’s design can lead to consequential post-production issues.
If your cooling system’s layout wasn’t built with thermal management in mind, there’s no guarantee that attaching a fan or a heat sink to the system will even cool the right components. And if they do, they could lead to additional unforeseen problems like increased energy consumption or regulatory compliance issues.
Myth #6: Heat Pipes Aren’t Efficient.
Truth: Heat pipes are one of the most rugged and reliable heat transfer solutions.
There are so many myths about heat pipes — that they’re too heavy, unreliable, or inflexible. Frankly, if you’ve had a poor experience with heat pipes, it’s more likely due to poor thermal contact issues rather than flaws in the technology itself.
Copper and water heat pipes, like the ones in laptops, have been known to last for decades. When designed with the correct materials and proper size for the given application, heat pipes can passively conduct heat away from the device, ensuring efficient cooling.
Visit our Heat Pipe Learning Center to find a full breakdown of compatible fluid and envelope pairings, temperature parameters, and limitations
Myth #7: I Have To Build My Thermal Solution To Determine That It Works Properly.
Truth: Advancements in thermal simulation tools can give skilled engineers the ability to predict the effectiveness of heat transfer given your product’s design.
Today’s thermal simulation tools can be precise, especially in the hands of trained engineers. Seeking out these simulations can reduce multiple prototyping cycles, minimizing time and production costs along the way.
ACT’s advanced engineers have developed reliable modeling methods and custom code across various thermal technologies that allow us to test and optimize the best method for your project’s requirements before any physical changes need to be made.
If you’re worried about keeping your project on schedule, consider trusting our team to provide design analysis support. In addition to modeling results, our team designs, builds, and evaluates the best solutions for your project’s requirements.
Myth #8: High-Performance Thermal Management Systems Are Too Expensive.
Truth: The right solution upfront prevents costly rework and failures down the road.
Cutting corners on thermal management may seem like a cost-saving measure, but it often leads to expensive consequences. High-performance systems are designed for reliability, ensuring your equipment operates efficiently without the risk of overheating, premature failure, or costly downtime. Investing in the right solution from the start means avoiding repeated redesigns, emergency fixes, and potential damage to your brand reputation if a system fails in the field. In the long run, doing it right the first time is the most cost-effective choice.
Work With a Team That Can Support You In Any Stage of The Thermal Design Process.
ACT’s thermal management team is equipped with the expertise to provide consulting, design and analysis, prototyping, small- or large-scale manufacturing, or product testing support.
