Rdr²
Unlocking the Potential of Thermoelectric Energy Through Precision Manufacturing
Thermoelectric generators (TEGs) are an increasingly promising solution in the pursuit of sustainable, efficient energy technologies. Using the Seebeck effect to convert heat directly into electricity, these solid-state devices offer quiet operation, minimal maintenance, and the potential to recover energy from a wide variety of sources—from industrial waste heat to off-grid and even space-based systems. As materials and methods continue to evolve, TEGs are poised to play a transformative role in how we harness and manage energy.
One Welsh Research & Development company, Rdr², is working at the forefront of this field with their early-stage thermoelectric generator design demonstrating strong potential. Rdr² identified an issue, the hand-built nature of their prototypes introduced unavoidable variability. In seeking a route to more consistent, scalable manufacturing, they engaged CEMET to assist with refining the production process using Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).
While the full scope of Rdr²’s technology remains commercially sensitive, the collaboration centred around building a repeatable, high-precision approach to support further innovation and real-world application.
Cracking the Heat Code
Initial prototypes relied heavily on manual techniques, which—though effective for proof of concept—were subject to performance inconsistencies due to human error and subtle material deviations. The challenge was to explore how modern design and manufacturing tools could bring consistency to the process without compromising the generator’s core design or performance principles.
Another key complexity stemmed from the environmental sensitivity of TEGs, especially with respect to humidity and temperature. Accurate testing under real-world conditions was critical for validating the improvements, yet traditional lab environments struggled to offer the precision needed. CEMET needed to build a flexible and modular testing and fabrication approach that could account for these external factors.
Engineering the Edge
The project began with a technical replication of Rdr²’s existing production workflow. This step helped CEMET map out each stage of assembly, identify areas of variability, and understand the intent behind the original design decisions.
From there, the team focused on improving consistency at the points of greatest sensitivity. A controlled mixing methodology was introduced to ensure repeatable preparation of internal materials. CAD tools were then used to redesign components such as assembly jigs and the housing framework to allow for tighter tolerances and greater mechanical precision. These designs were brought to life using laser cutting and 3D printing techniques, ensuring accuracy and repeatability.
The team also explored design enhancements, including increasing the mass of the thermal dissipation plates for improved heat flow and power generation, which was modelled and manufactured using CNC techniques. In parallel, environmental testing protocols were adapted to evaluate generator performance at varying humidity levels, offering practical insight into the stability and reliability of the newly manufactured modules.
Iterative rounds of testing were built into the workflow. Each design refinement was followed by controlled production and comparative evaluation, allowing the team to track improvements in open-circuit voltage, current output, and overall stability.
Brighter Sparks Ahead
CEMET successfully demonstrated that Rdr²’s hand-crafted thermoelectric generator design could be replicated through a more standardised and manufacturable process. By translating the original workflow into CAD models and CNC-compatible components, we were able to achieve comparable performance outcomes, confirming that the prototype’s results were not an artefact of inconsistency or manual variability.
This validation gave Rdr² confidence that their design approach was sound, and that it could be reproduced reliably without compromising on effectiveness. The introduction of CAD files, CNC-machined parts, and 3D-printed jigs has created a foundation for repeatable production, offering a clear route toward scalability and further refinement. While performance remained consistent with earlier iterations, the ability to recreate those results through a reliable process marked a key success of the collaboration
The work delivered not only a set of improved prototypes but also a complete report package, including CAD files, manufacturing instructions, and testing results. This will enable Rdr² to continue developing and refining their solution with greater confidence and clarity.
Although elements of the project remain confidential, the outcome highlights the powerful role of digital manufacturing in helping emerging energy technologies move from concept to viable product. Through careful process evaluation, iterative design, and a strong focus on repeatability, CEMET helped lay the foundation for the future of this promising energy innovation.
This project is funded by the UK government through the UK Shared Prosperity Fund and supported by Swansea City Council.