Sustainable Cooling Meets 3D Printing: MAGNOTHERM & Forward AM
MAGNOTHERM is on a mission to transform the cooling industry with its revolutionary magnetic cooling technology. Unlike conventional gas-compression refrigerators that rely on harmful refrigerants, MAGNOTHERM’s POLARIS beverage cooler leverages the magnetocaloric effect to provide a sustainable and energy-efficient alternative. To bring this cutting-edge solution to life, the team turned to Forward AM’s Ultracur3D® RG 1100 B resin, utilizing Creality 3D printers for both prototyping and end-use components.
Project Breakdown
Industry & Application
Sustainable cooling and refrigeration – leveraging magnetocaloric technology and additive manufacturing to create energy-efficient, gas-free cooling systems.
Solution & Material
Ultracur3D® RG 1100 B – a high-strength, ethanol- and water-resistant photopolymer resin – used with Creality 3D printers to manufacture complex, functional components for the POLARIS cooling system, including the Active Magnetic Regenerator (AMR).
Why Forward AM?
Forward AM’s expertise in high-performance photopolymers enabled MAGNOTHERM to develop intricate, durable, and chemical-resistant components that would have been impossible to manufacture using traditional methods.
A New Era of Refrigeration
Magnetic cooling works by using special metals that heat up when exposed to a magnetic field and cool down when the field is removed. By cycling this effect and using water to transfer the heat, the MAGNOTHERM‘S POLARIS system can achieve refrigeration without the need for harmful gases or compressors. This method not only makes cooling more environmentally friendly but also improves energy efficiency compared to conventional methods.
“At MAGNOTHERM, our vision is to revolutionize cooling technology by eliminating harmful refrigerants and maximizing energy efficiency. We believe in a future where sustainable, magnetocaloric cooling replaces traditional methods, reducing environmental impact while delivering superior performance.”
Jeffrey Pickett – Co-Founder & CPO at MAGNOTHERM
The Challenge: Pioneering a New Cooling Paradigm
Traditional cooling systems account for nearly 20% of global electricity consumption and are a major contributor to greenhouse gas emissions. To stay competitive in the rapidly evolving market, MAGNOTHERM needed manufacturing technology that could accelerate their speed-to-market. Initially, 3D printing was selected for rapid prototyping, but the benefits soon extended to production as well.
Beyond scalability, specific functional requirements drove material selection for key components like the Active Magnetic Regenerator (AMR), the heart of the POLARIS cooling system. This component required:
- High Rigidity & Strength: To withstand repeated magnetic cycles and operational stresses
- Complex Internal Geometries: The AMR contains integrated channels and check valves that could not be fabricated using traditional CNC machining
- Chemical Resistance: The material had to withstand continuous exposure to ethanol and water without swelling or degradation
The Solution: Ultracur3D® RG 1100 B for Performance and Reliability
When evaluating materials for their prototypes and final parts, MAGNOTHERM quickly identified Ultracur3D® RG 1100 B as the ideal resin for their needs. The rigid photopolymer provided the necessary strength, durability, and printability required for their components. After initial testing, the results confirmed what the data sheets promised, high mechanical performance and reliability.
The AMR component, a crucial part of the POLARIS system, was one of the most demanding to manufacture. Thanks to Creality 3D printers and Ultracur3D® RG 1100 B, MAGNOTHERM successfully produced:
- Highly intricate fluid channels to efficiently transport cooling liquids
- Integrated check valves that regulate the cooling process, simplifying the assembly
- Durable, ethanol- and water-resistant structures capable of long-term operation without degradation
By integrating Creality 3D printers into their workflow, the team was able to efficiently produce parts for their POLARIS refrigerator, benefiting from:
- Fast iteration cycles during R&D
- Consistent and precise prints for functional parts
- Cost-effective production of small-batch end-use components
Key Results
- Enhanced Product Development: Faster iterations enabled quicker refinement of the POLARIS system
- Optimized Performance: Rigid, high-strength components ensured the functionality and longevity of the cooling system
- Sustainable Manufacturing: Additive manufacturing reduced material waste and enabled localized production
“Using Forward AM’s Ultracur3D® RG 1100 B resin allowed us to manufacture complex, high-performance components that would have been impossible with traditional machining. The material’s strength, precision, and resistance to ethanol and water made it the ideal solution for our Active Magnetic Regenerative system.”
Milan Strauch – Development Engineer at MAGNOTHERM
“By combining magnetic cooling technology with 3D printing, MAGNOTHERM is proving that sustainability and innovation go hand in hand. Forward AM’s Ultracur3D® RG 1100 B plays a crucial role in bringing their vision to reality, delivering high-performance components that support a cleaner, more energy-efficient future in refrigeration.”
Jeffrey Pickett – Co-Founder & CPO at MAGNOTHERM
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Next Steps
Reference Links
- For more technical insights take a closer look at our material page: Ultracur3D® RG 1100 B
- Here you can find additional information on Forward AM's Pellet Portfolio: Ultracur3D® Resins
