Beyond improving efficiency, the CHESS thin-film technology uses remarkably less material — just 0.003 cubic centimeters, or about the size of a grain of sand, per refrigeration unit. This reduction in material means APL’s thermoelectric materials could be mass-produced using semiconductor chip production tools, driving cost efficiency and enabling widespread market adoption.

“This thin-film technology has the potential to grow from powering small-scale refrigeration systems to supporting large building HVAC applications, similar to the way lithium-ion batteries have been scaled to power devices as small as mobile phones and as large as electric vehicles,” Venkatasubramanian said.

Additionally, the CHESS materials were created using a well-established process commonly used to manufacture high-efficiency solar cells that power satellites and commercial LED lights.

“We used metal-organic chemical vapor deposition (MOCVD) to produce the CHESS materials, a method well known for its scalability, cost-effectiveness and ability to support large-volume manufacturing,” said Jon Pierce, a senior research engineer who leads the MOCVD growth capability at APL. “MOCVD is already widely used commercially, making it ideal for scaling up CHESS thin-film thermoelectric materials production.”

These materials and devices continue to show promise for a broad range of energy-harvesting and electronics applications in addition to the recent advances in refrigeration. APL plans to continue to partner with organizations to refine the CHESS thermoelectric materials with a focus on boosting efficiency to approach that of conventional mechanical systems. Future efforts include demonstrating larger-scale refrigeration systems, including freezers, and integrating artificial intelligence-driven methods to optimize energy efficiency in compartmentalized or distributed cooling in refrigeration and heating, ventilation, and air-conditioning (HVAC) equipment.

“Beyond refrigeration, CHESS materials are also able to convert temperature differences, like body heat, into usable power,” said Jeff Maranchi, Exploration Program Area manager in APL’s Research and Exploratory Development Mission Area. “In addition to advancing next-generation tactile systems, prosthetics and human-machine interfaces, this opens the door to scalable energy-harvesting technologies for applications ranging from computers to spacecraft — capabilities that weren’t feasible with older, bulkier thermoelectric devices.”

“The success of this collaborative effort demonstrates that high-efficiency solid-state refrigeration is not only scientifically viable but manufacturable at scale,” said Susan Ehrlich, an APL technology commercialization manager. “We’re looking forward to continued research and technology transfer opportunities with companies as we work toward translating these innovations into practical, real-world applications.”