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Prototyping and sampling for thermal management systems

Boyd Thermal by Eaton's mechanical, electrical, industrial and tooling engineers develop thermal management solutions that integrate multiple technologies into a single assembly. From early sampling through production-ready builds, our teams apply advanced modeling, design expertise and application knowledge to help you evaluate thermal performance, reduce development risk and move forward with confidence.

Our engineers work alongside your team in the way that best fits your program as a consultant, an extension of your engineering organization, or a full design and development partner. With Boyd Thermal by Eaton, you gain access to thermal management expertise and integrated prototyping support that help validate designs earlier, optimize performance and accelerate the path to production.

Quickly evaluate thermal management solutions

Early validation is essential when developing high-performance thermal management solutions. Boyd Thermal by Eaton's prototyping capabilities help you assess design intent, thermal performance and manufacturability quickly and cost-effectively, so you can refine concepts sooner and move into development with less uncertainty.

With shorter lead times and lower cost than production parts, Boyd Thermal by Eaton samples enable rapid concept evaluation and multiple design iterations before full prototyping. As programs mature, our prototyping capabilities help confirm form, fit, function and manufacturing readiness, supporting a smoother transition from thermal solution development into full production.

Samples and prototypes also support internal reviews, performance evaluations and customer discussions by making complex thermal solutions easier to assess and refine.

Eaton 3d vehicle engine design

Processes:

  • CNC machining 
  • Dip brazing
  • Friction stir welding
  • Internal component machining
  • Internal heat pipe fabrication & testing (groove, screen mesh and sintered powder)
  • Metal casting
  • Metal coating
  • Post-processing & finishing
  • Sheet metal fabrication
  • Vacuum brazing
  • Welding (TIG, MIG, plasma, inert gas, braze), including aerospace qualified weld capability Soldering and brazing (torch, vacuum, controlled atmosphere)
  • Wire EDM (electrical discharge machining)

General Prototyping

Capabilities:

  • 3D printing/ additive manufacturing – metals & polymers
  • CAD modeling
  • Custom hand or automated assembly
  • Pressure testing
  • Rapid tooling/production

Rapid prototyping

Our quick-turn prototyping capabilities build on early sampling work, allowing clients to further evaluate form, fit and function as designs move closer to production readiness.

Design manufacturability

Every solution that Boyd Thermal by Eaton engineers develop deeply incorporates Design for Manufacturability (DFM). We understand how cost, efficient fabrication and assembly affect the bottom line and ultimately define the success of your product.

Testing and validating prototypes

Boyd Thermal by Eaton engineering teams are well versed in testing and validation practices for a wide variety of industry standards and requirements to ensure designs meet your needs. With our dedicated design labs and testing facilities, engineers quickly and efficiently validate and test design ideas.

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