Conflux Technology Joins Honeywell-Led TheMa4HERA Consortium: Advancing Thermal Management Solutions for Next-Generation Aviation

The aerospace industry’s pursuit of Sustainability in aviation has reached a critical juncture with the integration of advanced thermal management technologies into hybrid-electric aircraft development. Conflux Technology, an Australian additive manufacturing specialist renowned for innovative heat exchanger solutions, has joined the prestigious TheMa4HERA consortium led by Honeywell. This marks a significant advancement in the quest for climate-neutral aviation by 2035. The collaboration represents a convergence of cutting-edge additive manufacturing capabilities with established aerospace expertise, addressing one of the most challenging technical hurdles in next-generation aircraft: managing heat loads projected to increase from current levels of 35–50 kW to potentially 300–1,000 kW in hybrid-electric regional aircraft. The partnership underscores the critical importance of thermal management systems in enabling the aviation industry’s transition toward sustainable propulsion technologies, while highlighting the growing role of innovative manufacturing techniques in solving complex aerospace challenges.

As aviation moves toward electrification and hybrid Propulsion, the need for efficient, lightweight, and scalable thermal management solutions becomes paramount. The TheMa4HERA project, under the Clean Aviation Joint Undertaking, is a cornerstone initiative in Europe’s strategy to decarbonize air travel, reduce greenhouse gas emissions, and maintain industrial competitiveness. Conflux’s expertise in additive Manufacturing and heat exchanger innovation is poised to play a vital role in solving the complex thermal challenges of next-generation aircraft.

The TheMa4HERA Consortium and Clean Aviation Initiative

The Thermal Management for Hybrid Electric Regional Aircraft (TheMa4HERA) project is one of the most ambitious collaborative efforts in European aerospace research, uniting 24 to 28 partners from 10 European countries under Honeywell’s leadership. This initiative operates within the Clean Aviation Joint Undertaking (CAJU), the European Union’s flagship program for transforming aviation toward a sustainable and climate-neutral future. The Clean Aviation program commands a total budget of €4.1 billion, dedicated to developing disruptive aircraft technologies that aim to reduce greenhouse gas Emissions by at least 30% compared to today’s best aircraft models.

The consortium’s formation reflects the aerospace sector’s recognition that thermal management is a critical bottleneck in hybrid-electric aircraft development. Unlike conventional aircraft, which generate relatively modest heat loads of 35–50 kW, future hybrid-electric regional aircraft must manage heat dissipation in the 300–1,000 kW range due to the integration of batteries, fuel cells, and power electronics. This represents a twenty-fold increase in thermal management requirements, necessitating revolutionary approaches to heat dissipation and system integration. TheMa4HERA aims to demonstrate solutions for this additional heat load while maintaining the lightweight and efficient characteristics essential for aircraft performance.

Honeywell’s leadership leverages decades of experience in thermal management design and manufacturing. The project is coordinated from Honeywell’s international development center in Brno, Czech Republic, the company’s largest R&D facility in Europe. Jan Ludvik, Engineering Director for Honeywell Technology Solutions in the Czech Republic, has highlighted the center’s extensive experience in international collaboration, including Clean Aviation and SESAR. The project’s technical scope covers research on thermal management architecture, air supply systems, air conditioning, system cooling, and comprehensive testing and demonstration activities. Partners like Collins Aerospace contribute specialized expertise in cabin air distribution, ensuring a holistic approach to aircraft thermal management from component optimization to system-level integration.

“Brno is Honeywell’s largest R&D center in Europe, and our dedicated team has extensive experience working with international partners from industry and academia.” — Jan Ludvik, Engineering Director, Honeywell Technology Solutions, Czech Republic

Conflux Technology’s Revolutionary Additive Manufacturing Approach

Conflux Technology’s entry into TheMa4HERA brings a transformative approach to heat exchanger design and manufacturing. Founded by Michael Fuller, who brings 15 years of motorsport engineering experience, Conflux has developed proprietary additive manufacturing techniques that enable the creation of heat exchangers with unprecedented performance characteristics. Their approach departs from traditional manufacturing by using advanced 3D printing to create complex internal geometries, impossible to achieve with conventional methods.

The core innovation lies in creating heat exchangers with significantly enhanced surface area density while maintaining optimal fluid flow and lightweight construction. According to company data, Conflux’s heat exchangers can demonstrate up to 300% higher heat rejection capability compared to conventional designs, with a 22% weight reduction. These improvements are achieved through the integration of intricate internal structures and optimized flow pathways, only feasible with additive manufacturing. As Michael Fuller notes, “We can introduce features that enhance heat transfer without inducing large pressure drops,” enabling higher heat transfer rates without compromising fluid flow.

Conflux’s manufacturing process utilizes EOS M 290 systems with EOS Aluminum AlSi10Mg material, selected after rigorous technical evaluation for their ability to meet ambitious performance targets. The company’s rapid development process allows for concept-to-product progression in just six months, with multiple prototypes built and tested thanks to the elimination of tooling requirements. Beyond design, Conflux employs proprietary post-processing methods to ensure component cleanliness and reliability, critical for aerospace and electric vehicle applications. Advanced verification, including high-resolution CT scanning at Australia’s synchrotron facility, ensures robust and repeatable manufacturing outcomes.

For TheMa4HERA, Conflux will develop lightweight, additive-manufactured heat exchangers for next-generation aircraft, contributing to both Air Cycle Systems (ACS) and Vapour Cycle Systems (VCS). Their involvement includes air-to-air heat exchangers for ACS and air-to-liquid exchangers for VCS evaporator and condenser applications. Fuller emphasizes, “Joining TheMa4HERA aligns with Conflux Technology’s commitment to delivering high-performance thermal solutions that enable energy-efficient, low-emission aviation.”

“Our additive manufacturing capabilities will help the consortium push the boundaries of thermal management design to meet the demands of hybrid-electric propulsion systems.” — Michael Fuller, CEO, Conflux Technology

Technical Challenges and Innovative Solutions in Hybrid-Electric Aviation

The shift to hybrid-electric propulsion in aviation presents unprecedented technical challenges. Traditional aircraft thermal management systems were designed for the predictable heat generation of turbofan engines and avionics. In contrast, integrating electric motors, batteries, fuel cells, and power electronics creates a thermal environment with variable heat loads and strict temperature requirements for optimal component performance and safety.

The scale of the challenge is stark: while current regional aircraft manage 35–50 kW of heat, hybrid-electric models must handle 300–1,000 kW. This increase is due to high-power electric motors, battery packs requiring precise temperature control, fuel cells generating substantial waste heat, and power electronics producing heat during energy conversion. Each subsystem has distinct thermal requirements, with batteries especially sensitive to overheating and cold, and fuel cells requiring stable temperatures for optimal electrochemical reactions.

Conflux’s additive manufacturing enables adaptive thermal management solutions, such as heat exchangers with geometry changes along the flow path to accommodate shifting fluid properties and temperature conditions. For example, in hydrogen fuel cell applications, internal geometry can be tailored to intensify heat transfer as air cools, a feat not possible with traditional manufacturing. TheMa4HERA will leverage comprehensive digital twin capabilities to simulate and optimize component-level requirements for any aircraft architecture, validated in full-scale test facilities at Fraunhofer IBP.

“TheMa4HERA aims to deliver scalable thermal technologies for hybrid-electric aircraft, supporting climate-neutral aviation by 2035.” — TheMa4HERA project statement

Market Context and Industry Growth Projections

The aerospace thermal management system market is a rapidly growing segment, driven by technological complexity and the demand for sustainable aviation. The global market was valued at approximately $3.2 billion in 2023 and is projected to reach $5.8 billion by 2032, with a compound annual growth rate of 6.5%. The hybrid-electric aircraft segment is even more dynamic, with a global market value of $2.80 billion in 2023 and projected growth to $465.60 billion by 2050, reflecting a compound annual growth rate of 21.7%.

North-America currently leads the hybrid-electric aircraft market, accounting for over 37% of the share in 2023, largely due to early adoption and regulatory support in the United States. Europe is expected to see substantial growth, bolstered by initiatives like Clean Aviation and the presence of key aerospace players. The broader electric aircraft market is also expanding, projected to grow from $8.8 billion in 2023 to $40.5 billion by 2033. Companies such as Electra.aero have already secured significant pre-orders for hybrid-electric aircraft designed for short takeoff and landing.

Regulatory pressures and industry commitments to net-zero emissions by 2050 are accelerating demand for advanced thermal management. Regional variations exist: Asia Pacific is poised for growth due to rising air travel and economic expansion, especially in China and India. The presence of established aerospace manufacturers and strong investment in North America underpins continued market leadership, while Europe’s public and private sector support for clean aviation ensures competitive positioning.

Funding Structure and Economic Impact

TheMa4HERA operates within the context of substantial EU investment in clean aviation, with the Clean Aviation Joint Undertaking’s €4.1 billion budget supporting disruptive aircraft technologies. TheMa4HERA itself is funded at €33.7 million, with €25.5 million from the EU and the remainder from private co-investment. The project involves 20 participants across Europe, with public funding covering approximately 75% of costs. The timeline runs from 2023 to 2026, with Technology Readiness Level (TRL) 5 targeted for several system components by 2025–2026.

The economic impact extends beyond R&D, strengthening Europe’s aerospace industrial base and fostering cross-border innovation. Clean Aviation’s second call for proposals allocated €380 million across eight projects, including €33 million specifically for hybrid-electric regional aircraft. This focus on near-term commercial applications aligns with the industry’s goal of achieving net-zero emissions and positions European companies to capture emerging market opportunities.

The project’s funding also supports critical testing infrastructure, such as full-scale demonstration facilities at Fraunhofer IBP, which will benefit the broader aerospace sector. The commercial deployment of resulting technologies is anticipated by 2035, providing a clear pathway from research to market and supporting long-term business planning in the sustainable aviation sector.

Future Implications and Technology Roadmap

TheMa4HERA’s success will be a pivotal enabler for sustainable aviation, with advanced thermal management systems targeted for TRL 5 by 2026 and subsequent flight testing and integration during Clean Aviation Phase 2. The solutions developed will be scalable to larger aircraft and adaptable to various electric and hybrid-electric propulsion architectures, supporting the industry’s climate-neutral ambitions for 2035 and beyond.

The integration of additive manufacturing into aerospace thermal management could transform manufacturing approaches across the industry. Conflux’s demonstration of 300% improved heat rejection and 22% weight reduction highlights the potential for broader adoption of these techniques. The project’s digital twin methodology and collaborative model set new standards for system optimization and cross-border innovation, providing a template for future aerospace research initiatives.

Conclusion

Conflux Technology’s participation in the Honeywell-led TheMa4HERA consortium marks a pivotal moment in sustainable aviation. The project’s goal of managing heat loads up to twenty times greater than current aircraft requires revolutionary thermal management approaches, making the collaboration between Conflux and Honeywell essential for achieving breakthrough performance.

With a €33.7 million investment, including €25.5 million in EU funding, TheMa4HERA exemplifies the strategic importance of thermal management in the transition to hybrid-electric propulsion. The technical innovations emerging from this collaboration, including additive-manufactured heat exchangers and digital twin-based system optimization, will have broad implications for aerospace manufacturing and sustainability. As the industry advances toward net-zero emissions by 2050, the solutions and collaborative models demonstrated by TheMa4HERA will be foundational to the deployment of next-generation aircraft.

FAQ

What is the TheMa4HERA consortium?
TheMa4HERA is a European aerospace research consortium led by Honeywell, focused on developing advanced thermal management solutions for hybrid-electric regional aircraft as part of the Clean Aviation Joint Undertaking.

What role does Conflux Technology play in the consortium?
Conflux Technology contributes its expertise in additive manufacturing and heat exchanger innovation, developing lightweight, high-performance heat exchangers for next-generation aircraft thermal management systems.

Why is thermal management important for hybrid-electric aircraft?
Hybrid-electric aircraft generate much higher heat loads due to batteries, fuel cells, and power electronics. Efficient thermal management is crucial for safety, performance, and enabling the transition to low-emission aviation.

What is the timeline for TheMa4HERA’s technology deployment?
TheMa4HERA aims for Technology Readiness Level 5 by 2026, with commercial deployment of resulting technologies anticipated by 2035.

How is the project funded?
TheMa4HERA is funded at €33.7 million, with approximately 75% from the EU and the rest from private co-investment, as part of the Clean Aviation Joint Undertaking’s €4.1 billion program.

Sources: Conflux Technology