Manufacturability of A20X printed lattice heat sinks

Laser powder bed fusion (LPBF) is a well-established technique for manufacturing compact and intricate lattice structures; however, surface roughness on curved surfaces remains a notable limitation. Triple periodic minimal surface lattices are beneficial for their lightweight, high-strength components and increased surface area for heat transfer, making them highly desirable in aerospace applications. This study designs five TPMS lattice-based heat sinks (Gyroid, Diamond, Lidinoid, Schwarz P, and Split P) utilizing two unit cell sizes (5 mm and 10 mm), with a consistent thickness of 1 mm and a base thickness of 2 mm, all within a specified volume of 15 × 15 × 15 mm3. Additionally, two cylindrical designs featuring varying periodicity for the gyroid and diamond lattices have been developed, utilizing unit cell sizes of 5 mm and 10 mm. The laser powder bed fusion technique was employed to fabricate A20x aluminium-based heat sinks, achieving excellent surface quality. Surface texture characterization of metal heat sinks was conducted using surface topography analysis with an optical profilometer and microstructural examination via scanning electron microscopy. Additionally, the relative density of the LPBF-printed heat sinks was measured to be over 99.5%.