Advanced Design and Manufacturing Approaches for Structures with Enhanced Thermal Management Performance: A Review

Abstract Advanced design methods and manufacturing techniques are crucial for developing thermal management structures, essential for the efficient operation of complex equipment. This study provides a thorough review of design methodologies and advanced manufacturing technologies for thermal management materials and structures. It identifies key challenges and critically evaluates the integration of innovative design principles, such as biomimicry and topology optimization, into thermal management solutions. The analysis delves into the evolution of design theories and preparation techniques, with a specific focus on modern needs and research directions, particularly highlighting components fabricated using additive manufacturing and their effectiveness in meeting advanced thermal management requirements. Current research focuses on designing structures tailored to various cooling methods, including air‐cooling, liquid‐cooling, heat exchanger cooling, and heat pipe cooling. These designs utilize phase change materials, electrocaloric cooling, and thermoelectric cooling materials to achieve optimal thermal management performance. Additionally, emerging innovations like solid‐liquid mixed heat transfer and the elastocaloric effect are garnering increased interest. Enhancing the design of thermal management structures through rigorous numerical simulations is critical for improving engineering applicability. However, overcoming challenges related to the commercialization and practical utilization of these advanced structures remains a pressing need.