Numerical and experimental analysis of hydraulic and thermal performance in additively manufactured topology-optimized heat sinks with different geometric features

With growing demand for efficient thermal management in high-power applications such as aerospace, energy systems, and microelectronics, this study explores a topology-optimized cooling channel design tailored for high heat flux conditions. The proposed design integrates numerical simulations and experimental validation to enhance thermal–hydraulic performance. The optimized 2 mm channel demonstrated a 55 % enhancement in both heat transfer coefficient and Nusselt number, a 60 % higher performance evaluation coefficient, and a lower thermal resistance of 0.0073 ℃/W. Experimental characterization of laser powder bed fusion fabricated AlSi10Mg alloy revealed anisotropic thermal conductivity governed by grain size variations, which was incorporated into simulations to improve predictive accuracy. Computed tomography and scanning electron microscopy analyses identified surface roughness as a key factor influencing pressure drop, with deviations attributed to additive manufacturing constraints. Experimental temperature measurements closely aligned with numerical predictions, showing that the optimized 2 mm channel reduced operating temperature by 9.6 % compared to the reference design. These findings highlight the balance between heat transfer efficiency and flow resistance, providing valuable insights into optimizing cooling channel designs for energy-efficient thermal management in high-performance electronics, renewable energy systems, and aerospace applications.