At this year’s Hannover Messe, visitors experience a sudden drop in temperature caused not by airflow, but by a metal structure being stretched and released.
This effect stems from a new cooling technology known as elastocalorics. It uses special metal alloys that heat up and cool down when they are mechanically stressed.
Researchers believe this method can replace traditional cooling systems that rely on harmful refrigerants.
The work is being led by Professor Paul Motzki and his team at Saarland University. They are working closely with 3D-printing experts led by Professor Dirk Bähre. Together, they are designing new shapes and structures that make this cooling process more efficient.
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At the exhibition, the team is showcasing small, shiny metal cubes. At first glance, they look like decorative objects. But these structures are carefully designed cooling elements, created using advanced 3D printing.
Motzki says, “We are taking elastocaloric technology to the next stage. Our research is still basic, but we are already building solutions for real-world use.”
The key idea behind these designs is simple: increase surface area. The more surface area a material has, the better it can exchange heat with air or water. By using 3D printing, the team can create complex, porous structures that allow fluids to flow through them easily. This improves cooling performance.
Unlike traditional systems, this technology does not rely on harmful gases. Instead, it uses a metal alloy made of nickel and titanium. This material is known as a shape-memory alloy.
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Shape-memory alloys behave differently from normal metals. They can change their internal structure when stretched or compressed. This change produces heat. When the stress is removed, the material absorbs heat and cools down.
Motzki explains, “When we stretch the alloy, it heats up and releases heat. When we release the stress, it cools and absorbs heat. This cycle allows us to move heat from one place to another.”
In simple terms, the metal itself becomes the cooling system. This process works through repeated cycles of stretching and releasing. Each cycle transfers heat away from a space, such as a cooling chamber.
Another advantage of this material is that it can sense its own condition. As the alloy deforms, its electrical resistance changes. This means the system can monitor its own performance without extra sensors.
Motzki says, “The material tells us how it is behaving. Resistance values show us exactly how much it is deforming.”
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The research team has been studying elastocaloric materials for more than 15 years. Their goal is to use this technology in cars, buildings, and industrial systems. They want to create cooling and heating solutions that are both energy-efficient and environmentally friendly.
So far, most experiments have used thin wires or sheets of the alloy. These are grouped together to increase surface area. Now, with 3D printing, the team is moving to more advanced designs.
The new structures are built layer by layer using additive manufacturing. This allows engineers to create detailed lattice shapes that were previously impossible. These shapes increase contact between the metal and the surrounding air or water.
Different designs are being tested to find the most efficient geometry. The goal is to maximize heat transfer while maintaining the structure’s strength and durability.
The need for better cooling technology is growing fast. Around the world, cooling and heating systems consume large amounts of energy. As temperatures rise, demand is expected to increase even more.
Elastocaloric systems offer a cleaner option. They run on electricity and do not use harmful chemicals. Their environmental impact depends only on the source of electricity.
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Global organizations have taken notice. The European Commission has identified elastocaloric cooling as one of the most promising alternatives to current systems. The World Economic Forum has also listed it among the top emerging technologies.
One major focus is durability. Cooling systems must operate continuously for extended periods. The materials must handle repeated stretching without failing.
Motzki says, “We are designing materials that can last for more than a million cycles. That is essential for real-world use.”
Even with strong materials, wear and fatigue are unavoidable over time. To address this, the team is developing designs that enable easy component replacement.
Motzki explains, “We are building systems that are easy to maintain. Parts should be simple to replace. That is key for everyday use.”
The researchers are also studying how to apply mechanical stress most efficiently. This includes optimizing how the material is stretched and released during operation.
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Students and young researchers are actively involved in this work. The project is integrated into academic programs focused on systems engineering and sustainable materials.
The goal is to prepare it for real-world deployment. What visitors see at Hannover Messe is not just a demonstration. It is a glimpse of a future where cooling systems are quieter, cleaner, and more efficient. A future where cooling does not depend on gases or compressors but on the simple act of stretching a piece of metal.
