This startup’s metal stacks could help solve AI’s massive heat problem

In a groundbreaking move, Alloy Enterprises is addressing a significant concern in the evolving landscape of artificial intelligence: the overwhelming heat generated by powerful GPUs. Following Nvidia's announcement in March regarding its upcoming Rubin series of GPUs, which could draw up to an astonishing 600 kilowatts of power, the challenge of cooling these energy-hungry data centers has never been more pressing. Traditionally, data centers have relied on various cooling methods, but with power consumption nearly doubling, innovative solutions are required. Alloy Enterprises has introduced a novel technology that transforms copper sheets into solid cooling plates designed for GPUs and peripheral components, which contribute to nearly 20% of a server’s cooling requirements. Ali Forsyth, the co-founder and CEO of Alloy, explained how this challenge was less critical when racks operated at 120 kilowatts, but as demand surges towards 600 kilowatts, effective liquid cooling solutions must be found for every component. The startup employs a unique process of additive manufacturing not through 3D printing, but by bonding metal sheets using heat and pressure. This method is more economical than traditional machining yet more affordable than 3D printing. The outcome is a seamless cold plate that resembles a solid block of metal, offering superior strength compared to typical machined products. Alloy's innovative approach creates cold plates with 35% enhanced thermal performance over competing solutions. This is achieved through a proprietary technique called stack forging, which allows for the production of intricate features as small as 50 microns, enhancing coolant flow efficiency. Working closely with major players in the data center industry, Alloy is adapting its technology from aluminum to copper, capitalizing on copper’s exceptional thermal conductivity and corrosion resistance. The response to their product has been overwhelmingly positive, with Forsyth noting a surge in interest following their June announcement, marking a pivotal moment for the startup as they position themselves at the forefront of cooling technology in the AI sector.