Heat transfer performance of compact TPMS lattice heat sinks via metal additive manufacturing
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-09-30 |
| Journal | Progress in Additive Manufacturing |
| Authors | Ganesh Chouhan, Avinash Kumar Namdeo, Ahmet GĂŒner, Khamis Essa, Prveen Bidare |
| Analysis | Full AI Review Included |
Executive Summary
Section titled âExecutive Summaryâ- Superior Thermal Performance: TPMS lattice heat sinks (Gyroid, Diamond, Lidinoid, Split P, Schwarz) demonstrated superior heat dissipation, achieving up to 44% greater heat transfer efficacy compared to conventional pin-fin designs of equivalent volume.
- Temperature Reduction: The Gyroid heat sink exhibited the lowest maximum operating temperature (96 °C at 30 W input), representing an 11% reduction compared to the conventional pin-fin heat sink baseline.
- Geometric Advantage: TPMS structures inherently offer approximately twice the surface area of conventional counterparts, optimizing thermal contact and heat transfer rate within a constrained volume (15x15x15 mm3).
- Manufacturing Method: Fabrication was successfully executed using Laser Powder Bed Fusion (L-PBF), enabling the production of intricate, monolithic geometries from high-performance A20X aluminum alloy.
- Uniform Heat Flow: TPMS lattices exhibited a more uniform temperature distribution and lower thermal gradients (2 °C to 2.5 °C difference between measurement points) compared to the non-uniform distribution observed in pin-fin heat sinks.
- Design Optimization: The study confirmed that thermal performance can be systematically enhanced by adjusting key parameters, including unit cell size (5 mm and 10 mm) and periodicity, validating the flexibility of TPMS architectures for specific thermal loads.
Technical Specifications
Section titled âTechnical Specificationsâ| Parameter | Value | Unit | Context |
|---|---|---|---|
| Material Alloy | A20X Aluminum (Al-Cu-Ag-Mg-TiB2) | N/A | L-PBF feedstock |
| Ultimate Tensile Strength (A20X) | 475 | MPa | Mechanical performance |
| Fixed Lattice Volume | 15 x 15 x 15 | mm3 | Volumetric constraint for all samples |
| Unit Cell Sizes Tested | 5 and 10 | mm | Design variable |
| Max Surface Area (Split P UC-5) | 5698.24 | mm2 | Highest measured surface area |
| Conventional Pin Fin Surface Area | 2344.94 | mm2 | Baseline comparison |
| Max Temperature (Gyroid, 30 W Input) | 96 | °C | Experimental result (11% lower than pin-fin) |
| Max Temperature Gradient (Split P UC-10) | 12.86 | °C | Simulation outcome (Peak - Lower Temp) |
| Convection Heat Transfer Coefficient | 20 | W/m2K | Simulation parameter |
| Emissivity (Fins) | 0.3 | N/A | Simulation parameter |
| L-PBF Laser Power | 200 | W | Concept Laser M2 system |
| L-PBF Layer Thickness | 30 | ”m | Optimized process variable |
| L-PBF Energy Density | 88 | J/mm3 | Optimized process variable |
| Chamber Atmosphere | Argon | N/A | Oxygen content maintained below 0.1% |
Key Methodologies
Section titled âKey Methodologiesâ-
Generative Design and Modeling:
- Five TPMS lattice types (Gyroid, Diamond, Schwarz, Lidinoid, Split P) were designed using nTopology software.
- Designs were constrained to a fixed volume (15x15x15 mm3) and varied by unit cell size (5 mm and 10 mm) and periodicity to maximize the surface area-to-volume ratio.
-
Additive Manufacturing (L-PBF):
- Samples were fabricated using a Concept Laser M2 system.
- Material: Gas-atomized A20X aluminum powder (40 ”m mean grain size).
- Process Control: Argon atmosphere (less than 0.1% O2), 20 ”m slice thickness.
- Optimized Parameters: Laser power 200 W, Hatch spacing 52.5 ”m, Layer thickness 30 ”m, Energy density 88 J/mm3.
-
Thermal Simulation (Numerical Analysis):
- Steady-state thermal characterization was performed using a partial differential equation model for three-dimensional temperature distribution.
- Boundary Conditions: Bottom face temperature fixed at 473 K; convection heat transfer coefficient 20 W/m2K; radiation emissivity 0.3.
-
Experimental Validation (Custom Test Rig):
- A customized test rig was constructed, featuring a copper cylinder block heated by a 980 W band heater to ensure uniform heat flow.
- Sample Mounting: Heat sinks were positioned atop the copper block using thermal paste.
- Data Acquisition: Temperatures were measured at three key points (left corner, center, right corner) using a digital temperature controller and a Keysight 34980A data logger to track stabilization and thermal gradients.
Commercial Applications
Section titled âCommercial Applicationsâ- High-Density Electronics Cooling: Essential for managing heat in compact digital components (CPUs, GPUs, power electronics) where conventional fin designs fail to meet volumetric constraints.
- Automotive and Aerospace: Ideal for lightweight structural components that also require high thermal dissipation, leveraging the strength and low density of L-PBF A20X alloy.
- Advanced Heat Exchangers: Manufacturing complex, high-surface-area heat transfer devices for industrial processes, HVAC, and energy recovery systems.
- Solid-State Lighting (LEDs): Providing efficient, compact thermal management solutions for high-power LED arrays, enhancing longevity and performance.
- Biomimetic Engineering: Utilizing TPMS structures for applications requiring high porosity, high surface area, and inherent self-supporting characteristics, such as catalytic converters or filtration media.
View Original Abstract
Abstract Nature-inspired triply periodic minimal surface (TPMS) lattices serve as exemplary models for advanced thermal management strategies. Their intricate geometric and topological configurations enhance surface area, porosity, and smooth curved walls, optimizing thermal performance across diverse applications. These attributes render TPMS structures exceptionally effective in augmenting heat sink performance within a constrained volume, outperforming conventional designs such as pin fin heat sinks. The present study evaluates the thermal performance of five L-PBF manufactured TPMS heat sinks (Gyroid, Diamond, Schwarz, Lidinoid, and Split P) relative to conventional pin-fin heat sinks of equivalent volume. The investigation focuses on the effect of unit cell sizes and periodicity on thermal performance, providing deeper insights into heat transfer mechanisms in TPMS-based structures. To accurately replicate the thermal characteristics, both numerical simulations and experimental testing were conducted. A customized testing system was developed to assess A20X aluminum heat sinks, revealing uniform heat flow across the lattice samples. Overall, this study indicates potential for improved heat transfer and validates the superior performance of TPMS heat sinks over traditional designs.