Core-Shell FDM Printing for Thermally Conductive Heatsinks

Solution Overview

Problem

Current 3D printing technologies, particularly FDM, struggle to produce thermally conductive heatsinks for luminaires due to the limited thermal conductivity of existing materials and the high cost and delivery delays of metal or aluminum components.

Innovation Solution

A method involving fused deposition modeling (FDM) using a core-shell structure with thermally conductive wires and a thermoplastic shell, where the core component is fed through the nozzle alongside or downstream, and a flexible mantle encloses the wires to maintain integrity and improve thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If graphite filled polymers are used for heatsinks, then thermal conductivity is improved, but thermal conductivity remains insufficient (around 5 W/m·K)

Engineering Contradiction:

Improvethermal conductivityVSAvoidheat dissipation performance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent uses composite materials by combining thermoplastic polymer matrix with thermally conductive fillers (graphite, metal particles, or fibers) to create a composite filament that achieves higher thermal conductivity than pure polymers while maintaining processability and cost-effectiveness

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the concentration, size, shape, and distribution parameters of thermal fillers within the polymer matrix to optimize thermal conductivity. By adjusting filler content from 20-80 wt% and controlling particle morphology, the material achieves superior heat dissipation compared to conventional graphite-filled polymers

Inventive Principle:

Principle #35Parameter changes

2Temperature

If metal printing is used for heatsinks, then thermal conductivity is improved, but cost and delivery time worsen

Engineering Contradiction:

Improvethermal conductivityVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent replaces expensive metal printing processes with affordable FDM 3D printing using polymer-based composite filaments. This substitution dramatically reduces material costs and eliminates the need for costly metal printing equipment while achieving sufficient thermal performance for lighting applications

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material state from metal to polymer-composite, enabling the use of standard FDM technology instead of expensive metal printing processes. This parameter change maintains thermal functionality while drastically reducing manufacturing costs and improving ease of production

Inventive Principle:

Principle #35Parameter changes

3Temperature

If metal printing is used for heatsinks, then thermal conductivity is improved, but delivery time worsens due to pre-ordering and storage requirements

Engineering Contradiction:

Improvethermal conductivityVSAvoiddelivery time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent replaces expensive metal printing processes with affordable FDM 3D printing using polymer-based composite filaments. This substitution dramatically reduces material costs and eliminates the need for costly metal printing equipment while achieving sufficient thermal performance for lighting applications

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent enables on-demand manufacturing of heatsinks using FDM 3D printing with pre-prepared composite filaments. This eliminates the need for pre-ordering and storing metal components, allowing immediate production when needed and significantly reducing delivery times

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If FDM is used with graphite filled polymers, then ease of manufacture is improved, but thermal conductivity remains insufficient

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidthermal conductivity

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent uses composite materials by combining thermoplastic polymer matrix with thermally conductive fillers (graphite, metal particles, or fibers) to create a composite filament that achieves higher thermal conductivity than pure polymers while maintaining processability and cost-effectiveness

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the concentration, size, shape, and distribution parameters of thermal fillers within the polymer matrix to optimize thermal conductivity. By adjusting filler content from 20-80 wt% and controlling particle morphology, the material achieves superior heat dissipation compared to conventional graphite-filled polymers

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the cost-effective production of thermally conductive 3D printed items with enhanced heat dissipation capabilities, reducing material costs and delivery times by using high-conductivity materials like copper, silver, or graphite wires.

Implementation Method 1

providing a shell component comprising a thermoplastic 3D printable shell material having a shell melting temperature Tms and/or a shell glass transition temperature Tgs; feeding the shell component into a nozzle of a 3D printer, the nozzle having a nozzle temperature Tn being equal to or greater than the shell melting temperature Tms and/or the shell glass transition temperature (Tgs)

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

providing a core component comprising a plurality of N thermally conductive wires and a flexible mantle enclosing the plurality of thermally conductive wires; a layer-wise depositing of the 3D printable shell material and the core component to provide the 3D item comprising a core-shell layer of 3D printed material, wherein the 3D printed material comprises a core comprising the core component

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12485605B2Method for 3D printing of a thermally conductive 3D item

Publication Date: 2025.12.02 SIGNIFY HOLDING BV

AI summary

The present invention relates to a method for manufacturing a 3D item (100) by means of fused deposition modelling (FDM), the method comprising the steps of: a) providing a shell component (5′) comprising a thermoplastic 3D printable shell material having a shell melting temperature (Tms) and/or a shell glass transition temperature (Tgs); b) providing a core component (2′) comprising a plurality of thermally conductive wires (3) and a flexible mantle (4) enclosing the plurality of thermally conductive wires (3); c) feeding the shell component (5) into a nozzle (6) of a 3D printer, the nozzle (6) having a nozzle temperature (Tn) being equal to or greater than the shell melting temperature (Tms) and/or the shell glass transition temperature (Tgs); d) a layer-wise depositing of the 3D printable shell material and the core component (2) to provide the 3D item (100) comprising a core-shell layer (100′) of 3D printed material, wherein the 3D printed material comprises a core (102) comprising the core component, and shell (105) comprising 3D printed shell material, wherein the shell (105) at least partly encloses the core (102).