Topology Optimization and Additive Manufacturing of Thermal Energy Components and Systems

Topology optimization of heat sinks

Three-dimensional Navier-Stokes equation for fluid flow and heat transfer equation, and their adjoint equations are solved in each design iteration.

Thermohydraulic tests show that the topology optimized heat sink has 2-fold increase in conductance over optimized parallel fin heat sink without much accompanying pressure loss (Sun et al IJHMT 2024)

3D topology optimization of heat sinks for liquid cooling

Topology optimization, additive manufacturing and thermohydraulic testing of heat sinks

Topology optimized heat sink
Cooling mechanism of TO design: better mixing and disrupting boundary layer
Topology optimized and Additively manufactured heat sinks
Additively manufactured heat sinks (printed in Thoma Lab)

Topology optimization of two-fluid heat exchangers

Two sets of Navier-Stokes fluid flow and heat transfer equations are solved, respectively, for fluid 1 and fluid 2.

Minimal wall thickness constraint is imposed to avoid leakage between fluids. Additive manufacturability constraint is also imposed to ensure powder removal from the resulting complex fluid channels.

With the same header, the TO HX outperformed the straight channel HX, reaching 50 kW, while the straight channel HX achieved 41 kW.

3D topology optimization and additive manufacturability of two-fluid heat exchangers

Topology optimization, additive manufacturing and thermohydraulic testing of high-temperature heat exchangers

Topologically optimized and additively manufactured two-fluid heat exchanger (50 kW) (printed by Thoma Lab)
Topologically optimized two-fluid core with overhang angle constraint

Topology optimization of phase-change material based latent heat thermal energy storage

A new method, interface filtering structure optimization, has been used to optimize the distribution of highly conductive materials in PCM matrix for enhancing energy storage capacity and efficiency.

Topology optimization of HCM/PCM composites for thermal energy storage

Interface‐Filtering Structural Optimization

Topologically optimized 3D highly conductive fins in phase-change material matrix