Data centers are popping up on maps across the globe these days. In 2025 alone, global supply grew by an estimated 20%. As artificial intelligence expands, the demand for reliable energy will only increase. Think of it this way: When you stream your favorite show, send a work email, or back up files to the cloud, a data center likely powers it. And every one of those centers depends on one thing to stay online: a reliable data center cooling system.
As data centers become denser and hotter, the role of liquid cooling or thermal management continues to expand. As much as 40% of a data center’s total energy consumption can be tied to cooling. Behind the servers and blinking lights lies a complex dance of airflow, temperature regulation, and thermal controls. Without it, heat builds up fast.
In this guide, we’ll break down the core types of cooling systems, explore emerging tech like liquid cooling, and explain how smart metal forming for cooling systems keeps everything running smoothly.
Why a Data Center’s Cooling System is Critical
The servers that power our digital world generate enormous amounts of heat. The American Society of Heating, Refrigerating, and Air Conditioning Engineers recommends an ideal temperature range of 64 to 81 degrees Fahrenheit.Â
Anything above this threshold can lead to serious issues:
- Hardware Failure: Servers are built for performance, not heat resistance. When internal temperatures spike, sensitive components degrade faster, hard drives crash, and CPUs may ultimately fail. Even short-term overheating can reduce equipment lifespan and create ripple effects across connected systems, making a modern data center cooling system crucial.
- Energy Waste: If your data center’s liquid cooling or thermal management system is outdated, cooling will require more energy. Inefficient airflow, overcooling, or poorly placed equipment leads to higher power usage effectiveness (PUE) scores, driving up operating costs.
- Full-Scale Outages: Worst-case scenario of an improper data center cooling system? Uncontrolled heat taking down the entire facility. Thermal-related outages are also some of the most expensive issues to resolve, with over 70% of outages costing $100,000 or more.
The Types of Data Center Cooling Systems
No two data centers will work or look exactly the same. Because of this, cooling strategies have to be tailored to each facility. Your choice of a data center cooling system will depend on factors such as server density, facility layout, and energy goals. Here’s a breakdown of the two most common cooling system types:
Air-Based Cooling:
Still the most widely used approach, air-based cooling systems rely on chilled air to remove heat from server racks.
Common methods include:
- CRAC Units (Computer Room Air Conditioner): Use refrigerants to cool air and push it into raised floors or underfloor plenums.
- CRAH Units (Computer Room Air Handler): Use chilled water instead of refrigerant and are often connected to external chillers or cooling towers.
- Hot/Cold Aisle Containment: A data center’s server racks are arranged in alternating rows, so hot exhaust air doesn’t mix with cool intake air.
Liquid Cooling for Data Centers:
As rack densities increase, liquid cooling is beginning to carve a larger role in the data center world. This is especially true in high-performance computing and hyperscale environments.
- Direct-to-Chip Cooling: Coolant flows directly to cold plates mounted on CPUs/GPUs, extracting heat at the source.
- Immersion Cooling: Entire servers are submerged in thermally conductive dielectric fluid that absorbs and removes heat.
The Role of Metal Forming for Cooling Systems
When crafting your data center’s cooling system, precision metal fabrication is key. From airflow control to equipment enclosures, well-fabricated sheet metal components help ensure that cooling systems do their job properly, consistently, and safely. So, how might this look?
Systems Built for Performance:
Air-based and hybrid cooling strategies rely heavily on proper containment and directional airflow. Server racks, ducting, containment panels, and perforated tiles all require precision cuts and bends to maintain tight tolerances.
If gaps are too large or panels are misaligned, cool air leaks or recirculates, reducing cooling efficiency and increasing energy usage. That’s why metal forming is critical for your data center’s cooling system.
Custom Enclosures:
Another benefit of precision metal forming for cooling systems is the ability to custom-tailor each cut to your exact needs. Custom-built server enclosures allow for optimized cooling at the rack level, as cabinets and racks can be fabricated to specs for:
- Passive and active airflow patterns
- Integration with cable management and sensor arrays
- Modular designs that accommodate changing cooling needs
Smarter Designs
Each bend of a data center cooling system plays its own role. That’s why RAS machines and software, including the Multibend-Center and Bendex 4.0, are made to bring true flexibility and reliability to every project.
If you’re building a data center and need precise metal forming for its cooling system, contact our team today for a consultation. We’ll help you find the right machine to fit your fabrication needs.
FAQs
What are the most common cooling systems used in data centers?
For high-density data centers, liquid cooling systems, including direct-to-chip, offer the most efficient heat removal, enabling compact layouts while maintaining performance and reducing energy consumption. Other facilities may rely on air-based cooling methods, including CRAC or CRAH systems.
How do data center cooling systems work?
Cooling systems work to keep data center servers within 64-81 degrees Fahrenheit. These systems ensure heat does not impact the performance of the facility.
What is the role of metal fabrication in improving cooling system performance?
Precision metal forming for data centers ensures proper airflow, supports custom enclosures, and reduces energy loss. This enables cooling systems to perform efficiently and reliably in high-density, heat-sensitive data center environments.
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