Parametric optimization of lattice structure heat sinks: An integrated computational and experimental approach

Abstract

Lattice structures have frequently been investigated for their unique mechanical and thermal properties and have been optimized for better performance for these characteristics. Their mechanical properties have shown amazing results and have been thoroughly investigated in many comprehensive studies. However, trending research is now investigating their thermal properties, specifically for heat dissipation or insulation applications. To further build on this research, our approach considers the design, manufacturing, modeling, and characteristics to develop a lattice structure optimized for heat sink applications. Utilizing efficient technologies in additive manufacturing, we employ fused deposition modeling (FDM) as the method of fabrication. FDM is currently the most popular method of additive manufacturing due to its simplicity and price. A microscopy analysis of a PLA-copper-infused filament verified that parts from a low-cost FDM printer can produce parts over 80% copper after debinding and sintering heat treatments. Using a design of experimentations, we have identified 3 variables in lattice structures, strut diameter, cell size, and cell type, and optimized these heat sinks for evaluation parameters of heat sinks. Using a statistical analysis software Design Expert, we have designed and run multiple heat sinks through computational fluid dynamics (CFD) simulations to predict heat transfer to analyze the trends of these variables to develop a heat sink. Our results found three optimized lattice structure heat sinks that we validated through CFD. Our study found characteristics that can be used in further research and testing to develop low-cost additively manufactured heat sinks. The method we utilized can also be used for future research for efficiently optimizing heat sinks.