Performance evaluation of copper cold plates manufactured via metal fused filament fabrication and alternative methods

Date

2026-01-01

Author

Bacikoglu, Mehmet Canberk
Yaman, Ulaş

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This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

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Additive Manufacturing (AM) provides notable advantages over traditional manufacturing techniques, particularly for creating parts with intricate geometries from diverse materials (Frazier, J Mater Eng Perform 23:1917–1928 2014). Metal Fused Filament Fabrication (M-FFF) is an emerging AM technique that uses composite filaments containing metal powders within polymer binders to produce metal components. This method supports the fabrication of various materials, including stainless steel, copper, tool steel, Inconel, and titanium. In this study, the M-FFF method is utilized to fabricate copper cold plates with internal liquid cooling channels designed for thermal management in electronic systems. Four distinct cross-sectional geometries—droplet, triangular, columnar, and finned—are developed to optimize supportless manufacturing and fluid flow efficiency. The pressure drop and thermal performance of these designs are assessed through numerical simulations and experimental testing. To compare the capabilities of M-FFF with conventional methods, similar cold plates are manufactured using Selective Laser Melting (SLM) and Friction Stir Welding (FSW). Results showed that the triangular cross-section yielded the lowest pressure drop, while the droplet cross-section demonstrated slightly improved cooling performance with reduced temperature values between copper cold plates. Numerical and experimental results of copper cold plates closely aligned in terms of pressure drop, confirming the reliability of M-FFF for fabricating complex designs. These findings illustrate the potential of M-FFF as a rapid and versatile technique for prototyping components with complex internal features, offering a practical solution for prototyping applications or industries requiring efficient cooling systems and intricate designs.

Subject Keywords

Cold plate design, Friction stir welding, Liquid cooling channels, Metal fused filament fabrication, Selective laser melting

URI

https://www.scopus.com/inward/record.uri?partnerID=HzOxMe3b&scp=105028133223&origin=inward
https://hdl.handle.net/11511/118663

Collections

Department of Mechanical Engineering, Article