3D printing helps Plunkett Associates develop high-performance heat sinks

Plunkett Associates was founded 10 years ago by Tim Plunkett, the authority on materials, molds and manufacturing technology. The company recently used its superb additive manufacturing expertise to create a range of high-performance heat sinks – primarily used to dissipate the heat generated by fine electronic components. These improved 3D printed components have a complex internal structure that cannot be manufactured with other manufacturing processes.

3D printing helps Plunkett Associates develop high-performance heat sinks

For many electronics manufacturers, air flow through natural convection is still the preferred method of cooling electronic devices. This method is inexpensive, easy to maintain and does not generate noise or electromagnetic interference. What are the disadvantages? Natural convection is limited by its scope and is difficult to use in systems with medium or high power output. Plunkett Associates hopes to break this limit this time to further expand the range of applications for convection cooling systems, for which the company began redesigning key components in the cooling system: heat sinks.

As the name suggests, a heat sink is a device that dissipates heat-dissipating electronic components. It is mainly used to ensure the service life of electronic components and prevent early failure of products. These heat sinks are mostly made of highly thermally conductive materials, such as aluminum or copper, which effectively dissipate heat from the electronic components to the surrounding air.

3D printing helps Plunkett Associates develop high-performance heat sinks

Designing a highly efficient heat sink is a challenging person. Manufacturers need to maximize the surface area of ​​the part and promote air flow as much as possible while minimizing costs. As part of the SAVINGs project funded by the Technology Strategy Board, Plunkett Associates turned to the Direct Metal Laser Sintering (DMLS) process to develop a heat sink with the perfect geometry. To this end, the company has developed a series of 3D printing designs based on the unique characteristics of the DMLS process. Each heat sink is first designed in a virtual form and then simulated using Computational Fluid Dynamics (CFD) software to evaluate the effect.

After the virtual test, the development team picked out the best five heat sinks, which were printed by 3T RPD using DMLS, and finally physical tests to confirm the accuracy of the virtual test. These five heatsinks offer significant performance improvements over standard models.

3D printing helps Plunkett Associates develop high-performance heat sinks

The success of this radiator project demonstrates another important industrial application of 3D printing technology . The hot additive manufacturing technology is expected to soon become one of the main means of cooling electronic components.

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