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Alloy Enterprises' Stack Forging Offers a Scalable Solution to Data Center Cooling Challenges

data centers liquid cooling AI Alloy Enterprises copper thermal management additive manufacturing
November 05, 2025
Viqus Verdict Logo Viqus Verdict Logo 8
Scalable Cooling
Media Hype 6/10
Real Impact 8/10

Article Summary

Alloy Enterprises is tackling a critical bottleneck in the rapidly expanding data center industry: cooling. With GPUs and other server components consuming ever-increasing amounts of power – potentially reaching 600 kilowatts per rack – traditional cooling methods are struggling to keep pace. The startup’s innovative stack forging process directly addresses this challenge. By transforming rolls of copper into seamless cold plates using a combination of heat, pressure, and laser cutting, Alloy produces components with 35% better thermal performance than machined alternatives. The key advantage lies in the elimination of seams, which can leak under high pressure, and the ability to produce smaller features – down to 50 microns – allowing for increased coolant flow. Alloy's process is particularly appealing because it can be customized to meet specific customer specifications, with the company handling much of the internal design. While currently focused on copper due to its superior thermal properties, Alloy is exploring aluminum alloys. The company’s approach represents a scalable solution to a pressing industry need, potentially driving significant improvements in data center energy efficiency.

Key Points

  • Data center power consumption is increasing dramatically, presenting a major cooling challenge.
  • Alloy Enterprises’ stack forging process creates seamless cold plates from copper, offering superior thermal performance compared to machined alternatives.
  • The technology allows for the production of smaller features, maximizing coolant flow and further enhancing cooling efficiency.

Why It Matters

The rise in data center power consumption is a fundamental constraint on the continued growth of AI and cloud computing. Alloy Enterprises’ solution is not simply a marginal improvement; it represents a potentially transformative approach to cooling, directly impacting the energy efficiency and operational costs of the world’s most critical computing infrastructure. This innovation is crucial as the demand for AI workloads continues to escalate, highlighting the importance of efficient cooling solutions in the digital age. For professionals in data center management, AI hardware, and energy efficiency, this news represents a vital development with significant implications for future investments and operational strategies.

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