Liquid Cooler Prototype for NVIDIA RTX 3090

Crafting a Diamond-Cut Liquid Cooler for NVIDIA RTX 3090: Nickel-plated copper base + transparent Acrylic top cover, size: (LxHxW) - 110x94x12.5mm.

With the increasing demand for high-performance computing, graphics card heat dissipation has become a key factor affecting system stability and performance. When a premium PC modding brand sought to create a limited-edition efficient and reliable liquid cooling system for NVIDIA's flagship RTX 3090 GPU, they needed more than just performance — they demanded artistry in engineering. Brightstar answered the call. 

Engineering FDM Analysis

Brightstar engineer inspecting CAD models of micro channel structures, using SolidWorks for 3D modeling to ensure that all dimensions and tolerances meet design requirements.

This water-cooled head needed to solve three problems at once:

1. The nickel-plated copper base required a mirror-flat contact surface (≤0.1mm variance).
2. Transparent Acrylic top covers needed leak-proof O-ring grooves capable of withstanding 10Bar pressure.
3. 0.5mm microchannels demanded surgical precision — any inconsistency would create hot spots.

Brightstar Approach for Challenge 3 Solution:

To achieve the stringent requirement, Brightstar used a DMG 5-axis machine center to carve microchannels with diamond-tipped tools, performing what they call "metal embroidery":

• Stage 1: Rough-cut channels with 0.6mm end mills.
• Stage 2: Refine contours using 0.5mm carbide tools.
• Stage 3: Ultrasonic bath polishing for burr-free edges.

Through these precision machining processes, the final product not only survived 48-hour pressure tests but reduced GPU temperatures by 23°C. The client was particularly impressed and satisfied with the functional cooler baseplate part.

If you are interested in our prototyping and want to discuss a purchase, please contact us.