Where precision meets excellence

We are a pioneering company in the field of thermal management. Our thermal solutions are not only lighter and more efficient than competition but also tailored to meet specific needs of each client. Our commitment to excellence and sustainability drives us to continuously push the boundaries of what's possible in thermal management.

At the heart of our operations are our proprietary design and analysis tools, developed in-house to ensure the highest standards of performance and reliability. These tools are founded in more than a decade of expertise in delivering lightweight heat exchangers using additive manufacturing (AM). By integrating design automation and optimization into our AM processes, we can deliver bespoke solutions with unmatched speed and robustness. Our unique end-to-end digital approach enables us to deliver products quickly without compromising on quality or performance.

Our team has expertise that spans across various high-demand industries, including aerospace, automotive, and energy. In these applications, our advanced thermal solutions play a crucial role in reducing fuel consumption and enhancing overall efficiency. Whether it's in the skies, or on the road, our heat exchangers are engineered to perform under the most demanding conditions.

We are not just developing products; we are shaping the future of thermal management. Join us on our journey to create a more efficient and sustainable world.

Established in 2020 to fill a gap in addressing increasing demand for novel thermal solutions, the company created a unique business model centered on innovative heat exchanger technology empowered by AM. While the use of AM is not new as has been utilized by some for heat exchangers, reliance on traditional design tools hindered its full potential. Guided by an experienced team with over 15 years of expertise in AM-based heat exchangers, we initiated the development of groundbreaking tools and validation techniques aimed at optimizing heat exchanger sizing, system integration, engineering analysis, and AM process file generation, fully harnessing AM advantages.

This endeavour led to the successful creation of a validated library of adaptive heat transfer geometries using advanced CFD & FEA optimization techniques, offering significant advantages over conventional methods. Capitalising on these milestones, the company secured EU fundings to develop a lightweight, multi-pass Air-Cooled Oil Cooler (ACOC) for the aerospace sector. Additional grant funding facilitated the characterization of structural integrity in heat exchanger core structures.

A pivotal breakthrough was achieved through an UK-funded project where a 57% further reduction in size and weight of the ACOC was realized through multidisciplinary design optimization and AM process thin wall optimization. We now have a dedicated digital streamline process that automatically generates a variety of heat exchanger designs optimized for additive manufacturing. These complex, ready-to-manufacture structures have undergone extensive analysis and validation, ensuring they meet the highest performance standards.

Further advancing into the energy sector, the company launched a cutting-edge recuperator product for micro gas turbine systems, delivering reduced size, weight, and high effectiveness >90%. To meet the growing demand for high-pressure H2 heat exchangers, we have developed a specialized product tailored for the hydrogen market that copes with high pressures. The latest innovation product includes a novel 2-phase condenser product with an integrated water separator for PEMFC cooling, addressing critical needs in fuel cell technology in automotive, aerospace, and power generation industries.

Morpheus Designs is also pioneering a cutting-edge liquid cooling solution for Net-Zero Flight as a key partner in the BRAVA project. Collaborating with MADIT and AIRBUS, our goal is to deliver an advanced fuel cell heat exchanger that offers superior performance, scalability, reduced mass, and lower drag compared to existing solutions.

The company continues its successful journey, leading commercial ventures and innovation projects while collaborating with clients across aerospace, automotive, and energy sectors, further strengthening its position as a pioneer in thermal engineering.