Design of internal structures to enhance the thermal performance of additively manufactured heat exchangers

Bio-inspired designs offer innovative solutions for optimizing heat exchangers, though their complexity often exceeds the capabilities of traditional manufacturing methods. Additive manufacturing (AM) enables intricate geometries with enhanced surface areas for improved heat transfer. This study presents a modular algorithm to integrate internal structures into heat exchanger designs, balancing thermal performance and manufacturability. A case study demonstrates the design, simulation, and production of internal structures, identifying the “Diamond Radial” structure as the optimal choice due to its high R-factor and potential to improve efficiency. Future work includes exploring multi-material components and designs for hydrogen storage and fuel cell applications, paving the way for more efficient, application-specific systems.