Design and fabrication of a TPMS-based micro heat exchanger via micro selective laser melting

The use of Triply Periodic Minimal Surfaces (TPMS) for high-efÏciency heat exchangers is emerging as a key area in additive manufacturing. TPMS lattices, such as the gyroid, provide excellent thermal and structural properties due to their high surface area-to-volume ratio, strength, and low material use. With advanced techniques like micro selective laser melting (Micro-SLM), developed at the Laserinstitut Hochschule Mittweida (LHM), it is now possible to fabricate these complex TPMS structures, which were not feasible with traditional methods. In this study, we demonstrate that manufacturing TPMS lattices with feature sizes as small as 100 µm via Micro-SLM significantly enhances heat exchanger performance, achieving heat transfer coefÏcients up to 12 kW/(m2 ∙K), over 300% higher than conventional plate heat exchangers. We examine the resolution of thin walls in these lattices and apply it to TPMS fabrication. Leakage tests confirm that these structures can withstand pressures up to 8 bar without leaks. Three heat exchangers were built, tested, and compared with a microchannel heat exchanger, confirming the superior thermal efÏciency of TPMS designs.

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