ENERGY-EFFICIENT HEAT EXCHANGERS USING ADDITIVE MANUFACTURING

Abstract

Additive Manufacturing (AM), commonly referred to as 3D printing, has emerged as a transformative technology in the design and fabrication of heat exchangers (HXs), enabling energy-efficient thermal systems across industrial, aerospace, automotive, and energy sectors. Unlike conventional manufacturing, AM allows the creation of highly complex and optimized internal geometries, leading to enhanced surface area, compactness, and improved thermohydraulic performance. This study presents a comprehensive review of the current state of research on AM-enabled heat exchangers, critically analyzes recent experimental and numerical findings, and proposes a methodology for evaluating thermal performance improvements relative to traditional designs. Key topics include geometry optimization, surface and microchannel augmentation, energy efficiency metrics, and fabrication challenges. Comparative results suggest AM heat exchangers can achieve significantly higher heat transfer effectiveness and surface-to-volume ratios while minimizing material use. Limitations and future research directions are discussed, emphasizing multi-scale design, material selection, and integration with advanced cooling technologies.