Multi-Objective Topology Optimization of Additively Manufactured Heat Exchangers

The higher design flexibility offered by additive manufacturing (AM) allows for radical improvements in the design and functionality of legacy parts. In this study, a flat-plate heat exchanger is designed and optimized using the ANSYS topology optimization module. Unlike conventional numerical optimization tools, the current optimization approach employs multiple objective functions, including mass reduction and maximization of heat transfer efficiency. Two unique, initial designs were used for ‘seeding’ the multi-objective topology optimization (TO) routines and the results are compared and discussed. Topology design and operating (boundary condition) variables were varied to elucidate major design sensitivities. The predicted heat transfer within the topology-optimized parts was validated using separate numerical methods. Constraints related to flow pressure drops and additive manufacturability were enforced. In both cases, the optimal design performed significantly better than the conventional heat exchanger in terms of thermal efficiency per unit mass.