FCT Develops Liquid Leak Detection Flex for AI Servers

Flexible Circuit Technologies Inc. (FCT), a Minnesota-based manufacturer of flexible circuits and advanced electronics, has unveiled its new Liquid Leak Detection Flex Assembly. This custom-engineered sensing solution is designed specifically for liquid-cooled AI servers, high-performance computing (HPC) systems, cold plates, manifolds, quick disconnects, coolant distribution units (CDUs), and other mission-critical electronics. As AI and HPC platforms increasingly adopt direct-to-chip liquid cooling, the need for early detection of coolant leaks has become paramount. FCT's flexible sensing assembly is built to conform to the complex geometry of cooling systems, enabling leak detection close to potential failure points while maintaining a thin, lightweight profile ideal for space-constrained server and rack environments.

The assembly can be customized for various applications, including sensing patterns, circuit geometry, connector interfaces, and multiple detection zones. Potential monitoring locations include supply and return quick disconnects, GPU and CPU cold plates, manifolds, coolant lines, CDUs, and server trays. The flex-based architecture allows OEMs and cooling-system manufacturers to integrate leak sensing directly into their equipment, rather than relying solely on facility-level detection. "The rapid growth of liquid-cooled AI infrastructure is creating a new need for thin, compact, highly customized leak-detection solutions," said Ray Cottrell, EVP of Flexible Circuit Technologies. "FCT's strength is designing flexible circuits around the customer's mechanical and electrical requirements. This concept allows us to bring that capability directly to cold plates, manifolds, quick disconnects, and server-level cooling assemblies where early detection can help protect high-value electronics."

FCT plans to collaborate with server OEMs and ODMs, liquid-cooling companies, cold-plate manufacturers, thermal-management suppliers, and data-center infrastructure providers to tailor the assembly to specific cooling architectures. The company's engineering team offers support for concept development, rapid prototyping, design-for-manufacturing, flex circuit fabrication, assembly, and scalable production. Flexible Circuit Technologies, Inc. (FCT), and its inTFlex (EMS division), provide specialty interconnects, including flexible circuits, catheters, rigid flex, flexible heaters, printed electronics/membrane switches, plastic moldings, and advanced EMS, from FPCA/PCBA to complete product box builds. With over 25 years in business, FCT has an internationally recognized design team and advanced manufacturing capabilities to support fast NPI and cost-effective manufacturing solutions in Asia. For more information, visit https://www.flexiblecircuit.com.