The Heat Exchanger
A 3D-printed copper heat exchanger utilizing triply periodic minimal surface geometry, validated through computational fluid dynamics (CFD) and finite element analysis (FEA), to manage high-flux thermal loads for solar cogeneration systems.
Challenge
The equation presented by Meer Lab was unbalanced. Their solar cogeneration system produced an excess of thermal energy, driving solar receivers past 150°C and threatening the operational limit of 80°C. The challenge was not to reduce the energy input, but to increase the efficiency of its extraction. The system required a radical improvement in thermal transfer within a constrained physical volume.
Solution
Conventional heat exchangers were inadequate. A linear increase in cooling performance required a non-linear increase in surface area. We engineered a solution whose geometry was dictated by thermal dynamics, not traditional manufacturing. A gyroidal internal structure of a triply periodic minimal surface was selected to maximize heat transfer across a minimal volume. Such a complex form can only be realized through additive manufacturing, so the design was specified for 3D-printed copper.
Result
The design was first proven in the digital domain. Thermal CFD analysis predicted the gyroidal lattice would dissipate the thermal load and stabilize the system at 70°C, well within the target range. The simulation was validated by the physical result. The final component was manufactured by Markforged and delivered ready for system integration, solving the thermal overload problem and, as a secondary benefit, reducing system costs by 30% compared to standard concentrated solar power heliostat designs.