An integration of topology optimization and conformal minimal surfaces for additively manufactured liquid-cooled heat sinks

This study introduces a novel methodology that integrates thermal-fluidic topology optimization (TopOpt) with advanced latticing techniques to design high-performance heat sinks tailored for additive manufacturing (AM). Inspired by a liquid cooling case study utilizing triply periodic minimal surface (TPMS) lattices, developed through conformal mapping by the nTop-Puntozero design team, the methodology focuses on replicating, adapting, and optimizing the original design to enhance flow characteristics while maintaining effective heat dissipation, adhering to Design for Additive Manufacturing (DfAM) guidelines and constraints. Four design variants were evaluated: a conventional serpentine cold plate, a geometrically similar replica of the reference design, and two hybrid TopOpt-latticing heat sinks. Numerical simulations were conducted to characterize performance metrics across a range of fluid pumping powers ( P pump ≤ 0.15 Watts). The results demonstrate that the proposed approach significantly enhances thermal-hydraulic performance compared to conventional designs. Additionally, prototypes of the optimized heat sinks were successfully fabricated using laser powder bed fusion (LPBF), validating their manufacturability. This work highlights the potential of hybrid TopOpt-latticing methods in achieving superior heat sink performance and underscores the necessity for holistic design workflows to fully integrate optimization, manufacturability, and application-specific requirements. Future research will focus on further development of these workflows and experimental validation of the numerical findings. • Presents a novel method combining topology optimization and TPMS lattices for efficient heat sinks. • Flow distribution is determined via multi-objective topology optimization, then conformal lattices are prescribed along interpreted flow paths. • The method conserves flow energy effectively while using the lattice's increased surface area to enhance heat dissipation. • Numerical studies indicate better thermal-hydraulic performance compared to conventional serpentine designs. • The heat sinks are printed in copper using an EOS M290 machine to investigate manufacturability.