Researchers from the University of Wolverhampton, in collaboration with UK Astronomy Technology Centre (UK ATC) and Diamond Light Source (DLS), have undertaken a pioneering study exploring the use of Copper Additive Manufacturing to optimize synchrotron absorbers. This project marks a step forward in utilizing 3D printing to enhance the performance and functionality of components in synchrotron systems.
Copper is well-known for its exceptional thermal and electrical properties, making it a crucial material in applications such as electrified transportation and green manufacturing. However, the challenges associated with processing copper using Laser Beam Powder Bed Fusion (PBF-LB) have historically limited its broader adoption in metal additive manufacturing. The collaboration between these institutions seeks to overcome these barriers.
Synchrotron Absorbers: Redesigning for Efficiency
The Centre for Engineering Innovation and Research (CEIR) at the University of Wolverhampton, which has been at the forefront of PBF-LB since 1999, played a key role in redesigning synchrotron absorbers. Using EOS M290 AM machines, the team was able to integrate conformal cooling channels and gyroid structures, which are critical for improving thermal dissipation and reducing material weight.
Preliminary tests show promising results. The redesigned absorber components demonstrated a temperature drop of up to 20%, an 80% reduction in weight, and a consolidation from 21 parts to 1. These improvements not only optimize the absorber’s performance but also simplify the manufacturing process.
Professor Arun Arjunan, Director of the Elite Centre for Manufacturing Skills (ECMS), emphasized the significance of this work, stating, “This project highlights the potential of Additive Manufacturing for thermal management. We will continue developing innovative solutions to meet the growing demand for efficient thermal management systems across industries.”
Future Research and Potential Impact
While the prototypes have shown remarkable results, further research and testing are planned to optimize the design fully. Given that there are approximately 30,000 accelerators and 60 synchrotrons worldwide, many of these systems stand to benefit from component redesign using additive manufacturing. The use of copper 3D printing could transform how these components are produced and improve their overall functionality.
The team’s findings on thermal performance and material properties will be detailed in an upcoming publication, providing greater insights into the practical applications of copper AM in the scientific community.
This breakthrough in 3D printing technology, specifically using copper, demonstrates a forward-thinking approach to thermal management and component efficiency, which could set a new standard for future synchrotron systems.
Source: metal-am.com
