Can You Take the Heat?

3D printing has transformed manufacturing by providing a flexible and economical way to create custom objects for a variety of purposes. One of its most notable impacts has been in the production of replacement parts for various devices, enabling users to fix and extend the life of their belongings. 3D-printed parts are also frequently used to build cases for single board computers and other electronic devices. From complex mechanical components to basic household items, the technology has allowed people to create customized solutions for their specific requirements.

In the early days of 3D printing, the designs were very basic and did not have the same level of sophistication as those produced through traditional manufacturing processes. However, as the technology progressed and people gained more experience, the quality of 3D-printed objects has improved significantly. Today, both hobbyists and professionals are able to create highly detailed and refined objects that are comparable to those made through conventional manufacturing practices. This evolution is due to the development of new 3D printing technologies, including improved printing materials, more advanced printers, and better design software.

Despite the progress that has been made, there are still challenges, particularly in the area of heat dissipation. Many 3D printed objects are made of materials like PLA, which is inexpensive and easy to work with but is also a thermal insulator. This can be a problem when 3D-printed objects are used in conjunction with electronics or other heat-emitting sources. Excessive heat can alter the fit of parts, or even melt them. And when computing devices are housed within 3D-printed cases, their performance can be degraded. As CPU temperatures rise, performance is throttled down to prevent damage.

A group at Pedro Lopes’ lab at the University of Chicago realized that good thermal design practices are lacking in large part because heat transfer is not an intuitive phenomenon. This fact makes the design of thermally-sound structures very challenging. In an effort to address this problem, they have developed a tool that they call ThermalRouter. ThermalRouter is a plugin for Autodesk’s Fusion 360, which is a frequently used computer-aided design application.

To use the tool, areas generating excessive heat first need to be identified. This can be done with a thermal camera or thermometer, by examining system logs, or by estimating values with the help of a datasheet. The temperature value is then assigned to a part using the ThermalRouter plugin. Next, users must specify which parts of their design can be modified to improve the thermal characteristics, and which must remain untouched.

Some additional information is then provided to tell ThermalRouter how aggressive to be in reducing temperatures, and what the budget is for the project. Using all of this information, the system will produce a number of design modification options that the user can choose from. These designs add heat spreaders and other features, composed of thermally conductive materials like nylon or metallic silicone, to channel heat away from its source. Since these materials are more expensive than commonly used plastics, ThermalRouter will try to minimize their use in line with the user’s budget.

The system also runs simulations to determine which design reduces heat by the largest amount. That information can be leveraged by the user as they choose the best option for their purposes.

The researchers noted that ThermalRouter’s solutions may not always be optimal. Rather, the primary goal of the project was to assist users in developing sound designs. It may be possible to incorporate machine learning into the system in the future to guarantee that optimal designs are generated. It is also notable that ThermalRouter can only produce passive cooling solutions, so there are limitations to just how much temperatures can be reduced. But in any case, this tool has the potential to give users a major boost in producing thermally sound designs.