For the last few years electric vehicles (EV) development has been the main driver for thermal management innovation. Efforts to improve battery performance, reliability and driving range paid off in new advanced thermal materials, new liquid cooling technologies, new ways to design and manufacture cold plates and heat sinks and collaboration across the supply chain to develop integrated and modular systems.
The slowdown in pure plug-in EV adoption in 2024 prompted a shift of focus within the automotive industry to hybrids, expanding the EV charging infrastructure and hydrogen fuel cell technologies. At the same time the artificial intelligence (AI) boom created new thermal challenges and opportunities in data centers, semiconductors and electronics. The aerospace, defense and energy industries also continued to innovate.
Our conversations with Thermal Management Expo attendees, exhibitors, conference speakers and other members of the broader thermal engineering community have offered valuable insights into the industry’s future directions. Keep reading to discover the 5 trends we will keep an eye on in 2025.
1 – The AI Revolution Driving Innovation in Data Center, Semiconductors and Electronics Cooling
Hyperscale data centers are implementing increasingly novel cooling strategies to deal with the explosion in computing power demand for generative artificial intelligence (AI) and high-performance computing, replacing traditional air cooling with liquid solutions from immersion cooling to direct-to-chip cooling.
Ideally the problem would be solved at the chip level. Next-generation chips stack layers of logic, memory and sensors on top of each other, increasing the power density in the package with no room for heat dissipation. New tools and materials are developed to analyse and solve these thermal challenges, with broader applications in other microelectronics, including automotive chiplets, 5G telecom and avionics.
2 – Sensors, Simulation and AI Converging into Embedded Predictive Thermal Management
Advancements in sensor technologies, digital simulation and artificial intelligence (AI) will converge to enable breakthroughs in embedded predictive thermal management in 2025. The combination of these technologies will provide dynamic, real-time temperature monitoring and adaptive cooling strategies across various applications, from onboard automotive systems to data centers and electronics.
The ability of AI and machine learning to process large streams of real-time data will enable optimization in thermal systems to a degree never possible before. AI can automate thermal monitoring of high-voltage batteries, motors and inverters, keep temperatures in different parts of a system at an optimal level and predict and mitigate hotspots in real-time.
3 – Electric Aviation Stealing the Spotlight from Thermal Innovation in BEVs
Aviation so far has been the missing link in sustainable mobility, but that looks likely to change in 2025. Dozens of well-funded startups have emerged in previous years to develop electric vertical takeoff and landing (eVTOL) aircraft or regional electric planes. Leading global airplane manufacturers also have their own projects to decarbonize aviation, generally involving hydrogen fuel cells and Sustainable Aviation Fuel (SAF).
Thermal management is a key factor in overcoming remaining weight and efficiency challenges and make electric aviation commercially viable. Some of the thermal solutions in electric aviation are built on innovations developed for battery-powered electric vehicles (BEV), but the field is inspiring thermal engineers, material scientists and specialist technology companies to reach further.
4 – Thermal Management Solving Bottlenecks in Net Zero Energy Infrastructure
Thermal management in 2025 will continue to play a key role in addressing bottlenecks in the energy transition, industrial decarbonization and grid optimization. Efficient thermal management is used in power electronics and inverter systems to support renewable energy integration into the grid.
Thermal energy storage systems can help stabilize grids by storing excess energy from renewables for release during demand peaks. Thermal management is critical for solar panels, wind turbines and geothermal systems.
Charging networks for electric mobility require thermal management. The high currents demanded by extreme fast charging (XFC) and megawatt charging for electric trucks and buses put heavy cooling requirements on the charging stations.
Trend 5 – Graphene and Other Material Advances Transforming Electronics Thermal Management
Graphene has been reshaping thermal management in electronics since the early 2010s. Graphene-based thermal interface materials (TIMs) have improved heat transfer between component, enabling better cooling for processors, power electronics and LEDs. Incorporation of graphene clusters into phase change materials has drastically improved their thermal conductivity
Graphene-based heterostructures combining graphene with hexagonal boron nitride (hBN) began drawing attention for practical applications five years ago and have been used experimentally in electronics and sensing. 2025 could be a pivotal year for targeted applications like deep-UV LEDs and niche photonics, although full commercialization seems further in the future.
Nanomaterials, like graphene and carbon nanotubes, are materials with structural components that have dimensions in the nanometer scale. Ceramic nanomaterials or nanostructured oxides are gaining traction in thermal management applications, such as EV batteries, energy harvesting in solar systems and thermal barrier coatings in high-temperature systems.
Don't Get Left Behind
Thermal Management Expo 2025 is the premier platform for professionals to connect with industry leaders, source innovative solutions, and stay ahead of the competition. Whether you're looking to optimize your supply chain, improve system performance, or address specific thermal challenges, this event is where business meets innovation. Engage with exhibitors offering tailored solutions, attend technical sessions addressing your industry’s most pressing issues, and build partnerships that drive growth and competitive advantage.
The 2025 edition takes place on April 29-30 in Novi, Michigan, USA and is free-to-attend.
Find out more about attending the exhibition and conference here.
