This project will integrate thermo-electric heat scavengers and attendant heat management systems into a single-piece, high thermal conductivity, structural part made of nano-structured Copper (free of toxic Beryllium). This will allow optimum energy harvesting from the waste heat of hot fluids. Single-piece manufacture will enable improved safety through vastly improved leak-tightness and structural integrity of the installation with minimised space usage. Copper is a relatively abundant metal, ideal for heat management applications due to its high thermal conductivity. However, bulk copper is too weak at temperature to provide structural strength. The ultimate strength of a material comes from the chemical bonds that hold it together. Like a zip fastener, it is hard to pull the zip apart (break the bonds) all at once. However, materials have very small defects (“dislocations”), which can move easily through the material, sequentially breaking individual bonds (like a zip unfastening) to generate permanent deformation (plasticity). Thus, bulk materials are generally very much weaker than their theoretical strength. Industrial trial and error has found that introducing different atom sizes, particles, grain boundaries and plastic work, can all increase the strength of a material. Even test-size affects the measured material response; “smaller is stronger”. Recent research has found a way to combine these effects to predict the strength of crystalline materials. ‘Strength is driven by length’; the average distance between different constraints on dislocation source size and motion. A ten-fold increase in strength can be achieved by engineering nano-scale lengths into materials. This project will utilise and contribute to a Joint facility established by QMUL and CU with the aim to develop an electro-chemical deposition process to deposit multiple (or single) materials, with a controlled local composition and nano-length-scale. This process will allow tuning and spatial variation of both elastic and plastic local properties in a single-piece part. Nano-structuring of the part will generate the increases in the strength of materials necessary to allow simple, high thermal conductivity elements (e.g. Cu) to be used as structural materials in pipes and manifolds handling fluids at elevated temperatures. Multi-phase designs will enable retention of strength at high temperatures. Current energy harvesting relies on retrofitting of parts, where mounting and heat management are achieved by the joining of multiple parts with attendant inefficiencies in heat transfer and the risk of leaks at relatively low pressures. In circumstances where energy is being recovered from fuels systems or other flammable liquids this is a severe safety hazard. Manufacture in a high thermal conductivity material, with integrated heat management, and the ability to fit in hotter environments, will greatly improve the thermal efficiency of the energy harvesting system.