A Review on Additive Manufacturing of Topology Optimized Microchannel Heat Sink

Microchannel heat sinks (MCHSs) have become essential for efficiently dissipating heat from high-power density components in various sectors, including electronics, aerospace, power systems, and medical devices. The recent advancements in additive manufacturing (AM) have revolutionized the fabrication of MCHSs, enabling multi-material construction, reducing production time and material waste, and overcoming the limitations of conventional manufacturing techniques. This review focuses on the application of AM in the development of topology-optimized MCHSs, offering insights into how AM technologies are transforming chip cooling solutions. We provide a comprehensive overview of the materials utilized in MCHS fabrication, including metals, alloys, ceramics, polymers, and nanocomposites. Additionally, the review highlights state-of-the-art designs, case studies, and commercial applications of AM in MCHS development. The findings suggest that AM can substantially enhance the thermo-hydraulic performance of topology-optimized MCHSs. As AM technologies continue to evolve—particularly in areas such as feature resolution, dimensional accuracy, surface roughness control, and material diversity—this review serves as a valuable resource for researchers and engineers navigating the rapidly advancing field of MCHS design.