Engineers at the University of Wisconsin-Madison have created a heat exchanger with complex internal channels that outperforms traditional designs. The team used topology optimization to develop twisting fluid pathways that improved heat transfer efficiency. This innovative design was then manufactured using laser powder bed fusion, a metal 3D printing technique.
“Traditionally, heat exchangers flow hot fluid and cold fluid through straight pipes, mainly because straight pipes are easy to manufacture,” says Xiaoping Qian, a professor of mechanical engineering at UW-Madison. “But straight pipes are not necessarily the best geometry for transferring heat between hot and cold fluids.”
Testing showed the optimized design achieved 27% higher power density compared to conventional straight channel designs. This improvement allows for more compact and lighter heat exchangers, particularly valuable in aerospace and aviation applications. The team published their findings in the June 1, 2025 issue of the International Journal of Heat and Mass Transfer.
The research stands out because it successfully bridges computational design and practical manufacturing. The team implemented a patented technique called projected undercut perimeter that ensures complex designs remain manufacturable. Professor Qian noted this practical focus: “Optimizing design on the computer is one thing, but to actually make and test it is a very different thing.”
High-temperature heat exchangers are critical components in many technologies, including aerospace, power generation, and industrial processes. This work demonstrates how additive manufacturing enables more efficient designs that were previously impossible to produce with traditional manufacturing methods.
Source: engineering.wisc.edu