Microchannel heat exchanger performance depends on tightly controlled channel dimensions, wall thickness, and surface condition. Small deviations in channel width or spacing can alter local flow velocity and pressure distribution, influencing both convective heat transfer and overall thermal efficiency. In dense arrays, cumulative geometric variation may lead to uneven flow distribution across the core, reducing performance predictability.
 

High-temperature nickel-based alloys such as Inconel present additional manufacturing challenges due to their strength and work-hardening behavior under conventional machining. Mechanical cutting forces can introduce localized deformation in thin-wall sections, while secondary finishing steps required to access internal passages may increase process complexity. In tightly packed microchannel designs, maintaining dimensional stability during machining becomes increasingly difficult as wall thickness decreases.
 

PECM removes material through controlled electrochemical dissolution without physical tool contact. This approach supports the formation of narrow internal channels and thin walls while reducing the risk of mechanically induced distortion. Because the process is governed by cathode geometry and pulse parameters rather than cutting force, feature consistency can be maintained across repeated channel arrays.
 

Internal surface condition also influences long-term performance. Surface irregularities may contribute to unintended turbulence, localized stress concentrations, or initiation sites under thermal cycling. By enabling controlled internal finishing within conductive alloys, PECM supports repeatable channel formation and surface continuity in geometries that are otherwise difficult to access through conventional tooling.
 

As aerospace systems pursue higher thermal efficiency and more compact packaging, microchannel density increases and tolerance windows narrow. Manufacturing repeatability becomes integral to design viability. Through custom cathode development and controlled pulsed electrochemistry, Voxel supports production-scale replication of complex microchannel heat exchanger components where flow uniformity, thermal performance, and structural reliability must remain tightly controlled.