Research collaboration develops advanced copper Additive Manufacturing process for heat sink design
December 11, 2024
ToffeeX, London, UK, in collaboration with Imperial College London and the University of Wolverhampton, has developed a design framework that brings multiscale analysis to physics-driven design. At the point of use, this method is said to fully capture thermo-fluid behaviour without the use of computational fluid dynamics (CFD). The University of Wolverhampton has now manufactured the first test specimen created with this method.
Multiscale modelling is reported to offer a computationally efficient solution to the challenges posed by traditional CFD. It models complex systems by solving a series of decoupled smaller systems, which are then assembled to accurately replicate the full behaviour. The decoupling is able to reduce computation time while maintaining high resolution.
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In parallel, the University of Wolverhampton has used its 400 W EOS M290 Laser Beam Powder Bed Fusion (PBF-LB) technology to manufacture these designs in high-purity copper. Known for its high thermal conductivity, copper has traditionally presented challenges in Additive Manufacturing due to its reflective properties. The goal of this partnership was to overcome those obstacles, producing copper heat sinks with enhanced precision and durability, thus showcasing the potential of PBF-LB AM technologies.
Professor Arun Arjunan, director of the university’s Elite Centre for Manufacturing Skills (ECMS) and Centre for Engineering Innovation and Research (CEIR) stated, “Working with ToffeeX, and Imperial College London pushing the boundaries of [PBF-LB] copper printing and heat sink design highlights the potential of Additive Manufacturing and thermal management. By combining our expertise in advanced materials and 3D printing technologies, we will continue to develop innovative solutions that meet the growing demand for efficient thermal management systems across various industries.”
This collaborators have stated that this should mark a significant step forward in both Additive Manufacturing and multiscale modelling, and has a promising future for heat sink design. The collaboration highlights the power of interdisciplinary teamwork to expand technological boundaries.
