Heat Exchanger Plates

Precision Etched Heat Exchanger & Cooling Plates

For Compact, High-Performance Thermal Systems

Switzer produces chemically etched heat exchanger and cooling plates for applications where precise heat dissipation and fluid flow control are non-negotiable. Our photochemical etching process creates intricate channel geometries in a range of metals, producing lightweight, burr-free, high-tolerance plates that conventional manufacturing methods cannot replicate. From a single prototype to full production volumes, we combine engineering expertise with a repeatable, cost-effective process built to meet your exact specifications.

Request A Consultation

Expertise Across Industries

Learn more about the specific ways Switzer can support your thermal management needs.

Thermal Management

The Precision That Performance Demands of PCHE & MCHE

Channel Depth & Width Tolerances

Our chemical etching process delivers channel geometries held to tight dimensional tolerances, so fluid dynamics behave as modeled, heat transfer coefficients remain predictable, and every plate performs to specification.

Process Control

Switzer's manufacturing process is built around repeatability. From chemistry management to etch depth verification, our process controls ensure that plate 10,000 performs exactly like plate one.

Inspection, Measurement & Validation Reporting

Precision at Switzer is documented, not assumed. Every production run is backed by dimensional inspection data, measurement reports, and validation documentation your engineering and quality teams can use directly in design verification and supplier qualification records.

Materials: Stainless Steel & Nickel-Based Alloys

Our current material capabilities include stainless steel and nickel-based alloys, selected for their corrosion resistance, high-temperature performance, and compatibility with aggressive process media. Both materials carry established certification pathways for regulated industries

Custom Coolant Channel Designs

Photochemical etching enables channel geometries that are simply not achievable with conventional machining or stamping. Switzer engineers work with you to optimize channel layout for your specific fluid, heat load, and pressure requirements.

Serpentine, spiral, or straight channel configurations
Variable channel depths within a single plate for localized cooling
Channels on one side or both sides of the plate (symmetrical or asymmetrical)
Micro-channel designs for high-density heat loads
Burr-free, stress-free features, no mechanical distortion
Tight dimensional tolerances with no hard tooling
Thin or thick plate sizes to suit structural and thermal requirements

Etched Heat Exchanger Plates | Heat Exchanger & Cooling Plates | Thermal Cooling Management

Flexible and Scalable Production

Our process scales seamlessly from prototype through production. Our engineering team will work with you to develop a manufacturable cooling plate for prototype and pre-production. When you are ready to scale up, you can count on receiving the same exact product at production volumes as you successfully tested at lower volumes.

Low-Cost Tooling

No hard tooling means you can test multiple channel designs quickly and efficiently to determine the optimized configuration for your application. This flexibility allows you to continue refining your design indefinitely without major cost penalties.

Rapid Prototyping

Different prototype designs can be turned around quickly to meet your internal timelines and get to market faster. As you scale, design tweaks remain low-cost and fast, supporting ongoing optimization through every stage of development.

Multi-Layer and Bonded Assemblies

For complex internal fluid paths, Switzer produces multi-layer channel plate assemblies joined by brazing, diffusion bonding, or welding. Each assembly is built for hermetic seals and full structural integrity at pressure.

Heat Exchanger Tube | Etched Heat Exchanger & Cooling Tube

Heat Exchanger Plate | Cooling Plate | Thermal Management Components

Applications Across Industries

RF & Microwave Systems

High-frequency power amplifiers, radar systems, and base stations where thermal output management is essential to signal integrity and preventing component overheating
RF power amplifiers, radar modules

Power Electronics & Electric Vehicles

EV battery packs, high-voltage inverters, IGBTs, and powertrain systems requiring precise temperature regulation for longevity and efficiency

Aerospace & Defense

Avionics, aerospace electronics, and ITAR-sensitive platforms where lightweight, high-precision components are required; microchannel cooling and high heat flux propulsion environments

Medical Devices

Advanced imaging systems including MRI and CT scanners, laser systems, and other equipment requiring reliable, controlled cooling

Telecommunications & Data Centers

High-power amplifiers, server infrastructure, and high-performance computing (HPC) environments where sustained thermal management prevents downtime

Renewable Energy

Renewable energy inverters and industrial power supplies requiring durable, efficient thermal solutions; nuclear modules, clean thermal control, precision temp systems

Our photochemical etching process is unmatched in precision for thermal management components. The values below represent standard capability. Tighter tolerances are available depending on material and design parameters.

Dimensional Specifications & Tolerance Capabilities

Material thickness:
.002’’ – .075’ (.05mm – 1.9mm)

Channel width:
Depending on Material Thickness

Channel depth:
.Depending on Material Thickness

Overall plate size:
Ideal plate size 18" x 24" or smaller
Larger sizes available on request [28" - 38" wide by 40" length]

Aspect ratio:
Maximum 2:1 (depth:width) for single-layer etching

Linear dimension tolerances:
±15% of material thickness (standard); ±0.001’’ – ±0.005’’ for feature dimensions

Depth tolerances:
±10% of specified depth

Positional tolerances:
± .002’’ standard; ± .001’’ for fine-feature / high-density patterns

Edge taper (etch factor):
1° – 3° typical, inherent to isotropic etching

Undercut:
Controlled to 15–20% of etch depth

Etched Heat Exchanger Plates Measurement Capabilities

Switzer can etch your thermal plates from a range of thermally and structurally optimized metals. Our experts will help you select the right material for your fluid compatibility, thermal conductivity, weight, and environmental requirements. We can also work with your sourced or preferred material.

Aluminum
Excellent thermal conductivity with lightweight properties; common in aerospace, automotive, and power electronics.

Stainless Steel
Corrosion resistance and durability for harsh or high-pressure environments.

Nickel alloys (Inconel and others)
High-temperature and corrosion-resistant applications.

We work with vendors to support your stack and bonding assemblies.

Brazing

Diffusion bonding

Welding

Adhesive bonding (lower pressure systems)

Cooling the Cloud: Why Microchannel Heat Exchangers Are Critical for Next-Generation Data Centers

Data centers are transforming. Modern AI applications and high-performance computing (HPC) demand massive amounts of power. This energy translates directly into heat. Traditional cooling methods are failing to keep up.

Capabilities to Support Your Exact Needs

Precision metal fabrication creates highly-accurate and detailed components. Our capabilities span the full spectrum to ensure every part meets your unique specifications and are delivered exactly when you need them.

Start-to-Finish Product Support

Trusted Vendor Partners

In-House Manufacturing & Engineering

Custom Packaging & Shipping

Learn More

Consult with a Technical Sales Expert About Your Heat Exchanger Plates Requirements

Thermal management is a core design requirement, and Switzer is built to support it at every stage. Whether you need a single-layer etched cooling plate, a multi-layer bonded heat exchanger assembly, or a fully custom solution for a demanding application, our team is ready to help. A consultation with our sales team is more than a quote, because Switzer does more than make your parts.