Case Design

The case was designed from 6061-T6 aluminum to dissipate the thermal losses through the fins on three sides. Aluminum was chosen for its thermal conductivity, cost, and ultimate strength [1].

The 3D model of the case design demonstrated that forced air convection must be used in the final design with approximately 7m/s of air flow to increase the convection coefficient. The case is able to dissipate 852.6 W through convection with forced air [2][3].

Transient analysis demonstrated that maximum power operation can be used for up to 10 seconds [4].

The case design was developed within manufacturing constraints such that it can be machined in the UVic machine shop by Hybrid team members.


[1] “ASM Material Data Sheet”, Asm Aerospace Specification Metals Inc., 2019. [Online]. Available:

[2] “Heat Sink Convection with Fins Calculator”, Engineers Edge, 2019. [Online]. Available:

[3] “Convective Heat Transfer”, Engineering Tool Box, 2019. [Online]. Available:

[4] Bahrami, Transient Heat Conduction. Simon Fraser University. [Online]. Available: