3D-printed heat sinks for thermal management of LED lighting

Indika U. Perera; Nadarajah Narendran; Jean Paul Freyssinier

doi:10.1117/12.2676953

3 October 2023 3D-printed heat sinks for thermal management of LED lighting

Indika U. Perera, Nadarajah Narendran, Jean Paul Freyssinier

Proceedings Volume 12670, 3D Printing for Lighting; 1267009 (2023) https://doi.org/10.1117/12.2676953
Event: SPIE Optical Engineering + Applications, 2023, San Diego, California, United States

Abstract

Today, the aluminum heat sink is one of the most expensive and heaviest components in an LED lighting product. Because manufacturers of LED lighting products face the pressure of having to reduce production costs, exploring ways to reduce manufacturing costs by way of using novel materials and manufacturing processes could be a potential solution. 3D-printed polymer-based composite heat sinks with suitable thermal properties and 3Dprinted metal heat sinks could help lighting fixture manufacturers reduce costs. 3D-printed heat sinks have the potential to be customized for increased functionality and visual appeal. This paper presented LED application-specific 3D-printed heat sink thermal performance characterizations. The heat transfer simulations showed that material with effective thermal conductivity values >15 Wm^-1K^-1 can potentially satisfy the thermal management requirements of a 50 W halogen equivalent MR-16 type LED integral replacement lamp. An experiment study was also conducted to evaluate the effect of Cu-plating of the PA-12 heat sinks. The Cu-electroplated heat sinks maintained an operating temperature below 105°C at the LED module case location for a thermal load equivalent to a 35W halogen equivalent MR-16 type LED integral replacement lamp. The 50μm Cu-electroplating thickness had equivalent performance to a 3D-printing material with an effective thermal conductivity of ~3Wm^-1K^-1. The 150μm Cu-electroplating thickness showed similar performance to a material with an effective thermal conductivity of ~6Wm^-1K^-1.

Conference Presentation

(2023) Published by SPIE. Downloading of the abstract is permitted for personal use only.

Citation Download Citation

Indika U. Perera, Nadarajah Narendran, and Jean Paul Freyssinier "3D-printed heat sinks for thermal management of LED lighting", Proc. SPIE 12670, 3D Printing for Lighting, 1267009 (3 October 2023); https://doi.org/10.1117/12.2676953

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