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<p>Due to their complexity, TPMS structures can only be manufactured through additive manufacturing processes, such as Powder Bed Fusion (PBF), which may also affect the structural integrity of the channels. This study compares numerical models using the Finite Element Method (FEM) with analytical approaches from the theory of thick-walled pressure vessels, seeking an efficient solution to optimize structural design without extensive computational simulations. The results indicate that the geometry, porosity, and thickness of the TPMS channels directly impact the equivalent stresses in the structure, highlighting a trade-off between thermal efficiency and mechanical strength. Furthermore, the article proposes a correlation to estimate the structural stresses of TPMS channels based on the Thick-wall Pressure Vessel stress model. The model can be applied to Gyroid and Diamond structures with a thickness of 0.5–1.0&#xa0;mm and unit cell size of 2.5–12.5&#xa0;mm within a 10% difference. This model can be applied to the preliminary design of printed heat exchangers for TPMS geometries to prevent mechanical static failures during operational conditions. This work provides a correlation between numerical simulations of TPMS structures and analytical solutions from thick-walled pressure vessel theory, enabling preliminary design of heat exchangers without the need for extensive FEM simulations. The proposed methodology demonstrates that Gyroid and Diamond structures can be reliably modelled within 10% deviation, offering a practical tool for balancing thermal performance and structural integrity in printed compact heat exchangers.The framework provides a simplified, validated tool for the preliminary design of additively manufactured TPMS heat exchangers, bridging analytical and computational approaches to reduce design cost and ensure mechanical reliability.</p>

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Structural response of triply periodic minimal surfaces under differential pressure in heat exchangers

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Rodrigo Silveira de Santiago,
  • Talita Sauter Possamai,
  • Kleber Vieira de Paiva,
  • Marcelo Okada Shigueoka,
  • Valter Estevão Beal

摘要

Due to their complexity, TPMS structures can only be manufactured through additive manufacturing processes, such as Powder Bed Fusion (PBF), which may also affect the structural integrity of the channels. This study compares numerical models using the Finite Element Method (FEM) with analytical approaches from the theory of thick-walled pressure vessels, seeking an efficient solution to optimize structural design without extensive computational simulations. The results indicate that the geometry, porosity, and thickness of the TPMS channels directly impact the equivalent stresses in the structure, highlighting a trade-off between thermal efficiency and mechanical strength. Furthermore, the article proposes a correlation to estimate the structural stresses of TPMS channels based on the Thick-wall Pressure Vessel stress model. The model can be applied to Gyroid and Diamond structures with a thickness of 0.5–1.0 mm and unit cell size of 2.5–12.5 mm within a 10% difference. This model can be applied to the preliminary design of printed heat exchangers for TPMS geometries to prevent mechanical static failures during operational conditions. This work provides a correlation between numerical simulations of TPMS structures and analytical solutions from thick-walled pressure vessel theory, enabling preliminary design of heat exchangers without the need for extensive FEM simulations. The proposed methodology demonstrates that Gyroid and Diamond structures can be reliably modelled within 10% deviation, offering a practical tool for balancing thermal performance and structural integrity in printed compact heat exchangers.The framework provides a simplified, validated tool for the preliminary design of additively manufactured TPMS heat exchangers, bridging analytical and computational approaches to reduce design cost and ensure mechanical reliability.