Projects

A direct-to-chip liquid-cooling architecture for high-power AI processors, combining an aluminum cold plate, optimized internal flow channels, and a modular rack architecture—designed not just to cool the machine, but to explore how efficiently we can move heat before the silicon hits its limits.

• The problem: AI accelerators are actively pushing towards power intensive procedures. The challenge is no longer simply removing heat. Nope. it is moving enormous amounts of heat uniformly and efficiently without creating localized hotspots, excessive pressure drop, or unsustainable pumping and cooling loads. 
• The solution (potentially): A liquid-cooling system that optimizes itself. Done by using real-time thermal feedback and trained AI to continuously reshape flow distribution across parallel microchannels. Flow patterns would be determined by current condition of the chip for example identified hotspots or pressure drops. 
• The progress: Simulation of a data centre condition has been done with aluminum extrusion racks. A small 1.5hp pump for water circulation installed and a liquid cooling radiator fan to dump excess heat. Potential micro channels to effectively remove heat are under testing.

SolidWorksANSYSMATLABHeat Transfer

Target heat flux

~100 W/cm² 

Plate material

Al 6061-T6 (testing)

Working fluid

Water

Measurement

Thermocouples

Drawings & photos · 04

CADAI Generated model of a potential cold plate flow channel

PHOTOModel data centre rack with aluminum extrusions

CADInstalled radiator dimensions

VIDEOSolidworks assembly 

Digital renderings · 00

A steel Warren-style truss built in two halves out of flat bar and angle, welded at the members, bolted through gusset plates at the nodes, then spliced at midspan. 

• Laid out a Warren pattern with verticals: diagonals take the shear, the top chord stays in compression, the bottom chord stays in tension, and nothing carries a moment it was not asked to carry.
• Sized the members off a method-of-joints pass and then checked the long diagonals for buckling instead of just yield. A tension member you can size on stress. A compression member is really a length problem.
• Kept every node concentric so the member centerlines meet at one work point. Offset the lines by half an inch and you have quietly added bending to a structure that was designed for axial load only.
• Gusset plates at the nodes with bolted connections, welded members into the plates. Bolts made the splice adjustable while I was still chasing alignment, welds made it stiff once it was.
• Tacked the whole thing first, checked square and camber, then filled in. Weld it all at once from one side and heat shrinkage pulls a straight chord into a banana, so the passes got alternated side to side.
• Built it as two half-spans and joined them at midspan, which kept the pieces small enough to fit up accurately on the table and made the hard part one clean splice instead of ten.
• Ground the toes back, checked for undercut and cracks, then loaded it. It held, and it did not make a single interesting noise, which is the highest compliment you can pay a weldment.

MIG WeldingFabricationStaticsSolidWorks

Process

MIG (GMAW)

Material

Mild steel flat bar & angle

Configuration

Warren truss, two half-spans

Connections

Bolted gussets + fillet welds

Drawings & photos · 06

PHOTOFinished Truss

PHOTOWarren Pattern

PHOTOBolted Gusset

PHOTODiagonal

PHOTOArc on, opinions off

VIDEOThe result

Digital renderings · 00

Designed and fabricated a sprint vehicle around a two-stage 3.85:1 gear drivetrain. Every gram removed was a gram that stopped arguing with the motor.

• Two-stage gear drivetrain (3.85 GR) tuned for the RPM–torque tradeoff over a 10 ft sprint.
• Laser-cut chassis iterated for mass, shaft alignment, and bearing friction.
• Tolerance stack-up and vibration mitigation validated through repeated timed runs.
• Final result: 1.35 s over 10 ft — 2.26 m/s average.

SolidWorksLaser CuttingPrototyping

Gear ratio

3.85 : 1

Distance

10 ft (3.05 m)

Best time

1.35 s

Avg speed

2.26 m/s

Drawings & photos · 03

PHOTOGear train

VIDEOSolidworks model of gear train

VIDEOFirst gear test

Digital renderings · 00