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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

NASA’s Evolving Ka-Band Network Capabilities to Meet Mission Demand

Space missions are increasingly demanding higher data rates to support the growth in information-intensive mission operations. This growth is reflected in planned and operational missions from low Earth orbit, such as the upcoming NASA-Indian Space Research Organization (ISRO) Synthetic Aperture Radar (NISAR) and Plankton, Aerosol, Cloud and Ocean Ecosystem (PACE) missions, to the future Artemis lunar campaign, and the recently launched James Webb Space Telescope (JWST) orbiting at the Sun-Earth L2 Lagrange point. JWST was the first L2 mission to be defined as a high data rate mission transmitting at 28 Megabits per second (Mbps), or 270 Gigabits of science data per day. ISRO and PACE anticipate achieving data throughputs of 5-40 Terabits per day. These data rates exceed the capabilities of S-band and X-band frequency allocations and are a key driver for migrating to the 26 GHz Ka-band frequency allocation. The NASA Space Communications and Navigation (SCaN) program has been preparing the networks to support this demand by pursuing critical Ka-band infrastructure. The status of current and evolving network capability, including the Near Space Network’s Initiative for Ka-band Advancement (NIKA), and the Deep Space Network’s Lunar Exploration Upgrades (DLEU), as well as profiling mission usage of Ka-band services, are discussed in detail. The push toward Kaband, is not only an opportunity for increased performance, but alleviates current challenges with contentious and cluttered spectrum access in S- and X-band. The paper provides an overview of these advantages and advanced techniques that optimize its use before the transition to optical communications becomes an imperative. The challenges and potential mitigations for missions considering selection of Ka-band network services are also discussed.

Ka-band↗
DOE OSTI2025

Diversifying the Materials and Technologies for the Future of Energy Storage

It is increasingly important to meet the growing global energy demand driven by factors such as population growth, electrification, and the rapid development of emerging economies, while minimizing the environmental harm caused by carbon dioxide emissions. Although fossil fuels remain an abundant and inexpensive energy source, there is a global consensus on the critical importance of addressing climate change and an increasing urgency to reduce carbon dioxide emissions without hindering economic growth. This challenge is particularly daunting due to the significant transformations required in electricity generation systems, transportation, and industrial processes. A significant portion of our energy still comes from burning fossil fuels, which poses harmful effects on the environment. Transitioning to renewable energy sources like solar and wind is essential, as these sources provide a low-carbon pathway for power generation and have become increasingly cost-competitive with fossil fuels. However, they face the inherent challenge of intermittency. Thus, energy storage systems (ESS) are essential not only to address this issue but also to accommodate the increasing adoption of electric vehicles (EVs). Lithium-ion batteries (LIBs) are still the predominant ESS used for these applications; however, they suffer from issues related to scarce and harmful resources, safety, and socio-economic impacts. This underscores the need for alternative energy storage systems beyond LIBs. Here, in this review, we discuss the diversification, repurposing, and recycling of ESS to meet the projected energy demand while minimizing environmental harm.

batteries↗
NASA NTRS2004

The minimal cost of life in space

The cost of keeping people alive in space is assessed from a theoretical viewpoint and using two actual designs for plant growth systems. While life support is theoretically not very demanding, our ability to implement life support is well below theoretical limits. A theoretical limit has been calculated from requirements and the state of the art for plant growth has been calculated using data from the BIO-Plex PDR and from the Cornell CEA prototype system. The very low efficiency of our current approaches results in a high mission impact, though we can still see how to get a significant reduction in cost of food when compared to supplying it from Earth. Seeing the distribution of costs should allow us to improve our current designs. c2004 COSPAR. Published by Elsevier Ltd. All rights reserved.

NASA Discipline Life Support Systems↗
DOE OSTI2026

Modelling belowground plant acclimation to low soil nitrogen – a heuristic optimality-based approach

Increased root growth to access greater soil mineral nitrogen resources and increased root exudation to stimulate microbial mineralization of soil organic nitrogen are widely observed plant acclimations to nitrogen limitation. However, their quantitative contribution to plant growth and ecosystem productivity remains largely elusive. Here, we present a novel optimality-based eco-evolutionary model in which plants dynamically regulate carbon partitioning between root growth and exudation to maximize their aboveground growth. Our simulations indicated that the availability of soil mineral and organic nitrogen as well as plant nitrogen demand and nitrogen uptake capacity shape optimal carbon partitioning between root growth and exudation. The simulated carbon allocation patterns aligned with empirical studies on belowground plant responses to varying soil nitrogen resources. Our eco-evolutionary approach represents a paradigmatic change in modelling plant nitrogen foraging, which is essential to generate hypotheses on optimal plant acclimation in future soil environments characterized by more erratic nitrogen availability.

Chakrawal, Arjun (ORCID:0000000345724347)↗
DOE OSTI2022

Defining Wind Energy Experience

Since 2015, the U.S. wind installed capacity has grown from 73 to over 120 gigawatts, creating jobs across many sectors and educational levels. The growth of the wind workforce will need to continue to meet the goal of 20% wind by 2030, as well as the Biden administration's goals to reduce greenhouse gas pollution by 2030, reach 100% carbon-free electricity by 2035, and achieve net-zero greenhouse gas emissions no later than 2050. Despite the needed and anticipated growth, there are challenges to meeting this demand. Research has consistently shown that it has been a challenge finding qualified applicants for open wind industry jobs. Between 2012 and 2018, the difficulty of finding qualified applicants increased from 62% to 68% according to industry respondents. In 2017, educational institutions and training programs reported that 67% of their students did not enter the wind energy industry. Research conducted in 2020 showed that 83% of interested workers had some or great difficulty finding job opportunities. In exploring reasons for this gap, the researchers found that challenges were primarily influenced by education, experience, and geography. This difficulty for wind industry employers, educational institutions, and the potential workforce is known as the "wind energy workforce gap." This report further investigates the experience aspect of this gap.

17 WIND ENERGY↗
NASA NTRS1975

Air transportation energy consumption - Yesterday, today, and tomorrow

The energy consumption by aviation is reviewed and projections of its growth are discussed. Forecasts of domestic passenger demand are presented, and the effect of restricted fuel supply and increased fuel prices is considered. The most promising sources for aircraft fuels, their availability and cost, and possible alternative fuels are reviewed. The energy consumption by various air and surface transportation modes is identified and compared on typical portal-to-portal trips. A measure of the indirect energy consumed by ground and air modes is defined. Historical trends in aircraft energy intensities are presented and the potential fuel savings with new technologies are discussed.

Mascy, A. C.↗
NASA NTRS1996

Pyroxene Homogenization and the Isotopic Systematics of Eucrites

The original Mg-Fe zoning of eucritic pyroxenes has in nearly all cases been partly homogenized, an observation that has been combined with other petrographic and compositional criteria to establish a scale of thermal "metamorphism" for eucrites. To evaluate hypotheses explaining development of conditions on the HED parent body (Vesta?) leading to pyroxene homogenization against their chronological implications, it is necessary to know whether pyroxene metamorphism was recorded in the isotopic systems. However, identifying the effects of the thermal metamorphism with specific effects in the isotopic systems has been difficult, due in part to a lack of correlated isotopic and mineralogical studies of the same eucrites. Furthermore, isotopic studies often place high demands on analytical capabilities, resulting in slow growth of the isotopic database. Additionally, some isotopic systems would not respond in a direct and sensitive way to pyroxene homogenization. Nevertheless, sufficient data exist to generalize some observations, and to identify directions of potentially fruitful investigations.

Nyquist, L. E.↗
NASA NTRS2021

Contribution of Meteorological Downscaling to Skill and Precision of Seasonal Drought Forecasts

Research in meteorological prediction on sub-seasonal to seasonal (S2S) timescales has seen growth in recent years. Concurrent with this, demand for seasonal drought forecasting has risen. While there is obvious synergy between these fields, S2S meteorological forecasting has typically focused on low resolution global models, while the development of drought can be sensitive to the local expression of weather anomalies and their interaction with local surface properties and processes. This suggests that downscaling might play an important role in the application of meteorological S2S forecasts to skillful forecasting of drought. Here, we apply the Generalized Analog Regression Downscaling (GARD) algorithm to downscale meteorological hindcasts from the NASA Goddard Earth Observing System (GEOS) global S2S forecast system. Downscaled meteorological fields are then applied to drive offline simulations with the Catchment Land Surface Model (CLSM) to forecast United States Drought Monitor (USDM) style drought indicators derived from simulated surface hydrology variables. We compare the representation of drought in these downscaled hindcasts to hindcasts that are not downscaled, using the North American Land Data Assimilation System Phase 2 (NLDAS-2) dataset as an observational reference. We find that downscaling using GARD improves hindcasts of temperature and temperature anomalies, but the results for precipitation are mixed and generally small. Overall, GARD downscaling led to improved hindcast skill for total drought across the Contiguous United States (CONUS), and improvements were greatest for extreme (D3) and exceptional (D4) drought categories.

Ryan A Zamora↗
DOE OSTI2026

Hybrid Cooling and Water Treatment for Resilient, Water-Self-Sufficient Data Centers

The continued growth of data center infrastructure is intensifying demand for freshwater resources, particularly in water-stressed regions, and is increasingly limiting sustainable capacity expansion. This work investigates a conceptual hybrid system that integrates freeze desalination with ultrasonic-assisted ice separation to enable on-site production of pure water from diverse sources, including seawater, brackish groundwater, and reclaimed industrial or agricultural wastewater. Simultaneously, the system produces low-temperature cooling streams that enhance heat removal in high power density computing environments. A process-level thermodynamic analysis is performed across a range of boundary and operating conditions, including variations in feed concentration, freezing temperature, and mass flow rate. The results are presented as performance curves relating feedwater concentration and target purified water output to the corresponding intake flow requirements, enabling estimation of source water demand per unit of Information Technology Equipment (ITE) energy consumption (kWh) across varying data center scales and operational scenarios. The corresponding electrical energy consumption for integrated cooling and water treatment is also evaluated as a function of system operating parameters and target water production levels. These results provide a basis for evaluating system feasibility across different conditions and for identifying parameter ranges in which integrated water treatment and cooling improve resource efficiency, thermal performance, and operational flexibility in data centers.

Elhefny, Aly [ORNL] (ORCID:0000000284907923)↗
DOE OSTI2025

Congestion Management Solutions for Enhanced Distribution System Operations with Aggregated Distribution Grid Resources Providing Grid Services and Market Participation

Microgrids and other aggregations of distribution grid resources (DGRs) are poised to actively participate in electricity markets and provide essential grid services in the coming years. In fact, DGRs already play such a role through behind-the-meter (BTM) demand response programs and small-scale BTM dispatchable generation initiatives. At the same time, the rapid growth of artificial intelligence (AI) and cryptocurrency datacenters imposes significant, often unpredictable, demands on the power distribution system. Aggregated DGRs can serve as flexible resources that help mitigate these pressures by using available transmission and distribution capacity more efficiently, supporting resource adequacy and other reliability services, and providing bridge strategies while long-term transmission infrastructure is being developed. The impacts this activity will have on distribution networks are not fully understood and could present significant challenges for distribution utilities due to capacity constraints and the need for congestion management. Technical issues include reverse power flow, variability and possible degradation of equipment integrity, voltage violations, and customer power quality concerns. These issues will likely intensify as electricity market operators across the United States implement Federal Energy Regulatory Commission Order 2222 over the next few years.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

The Utility of Satellites and Autonomous Remote Sensing Platforms for Monitoring Offshore Aquaculture Farms: A Case Study for Canopy Forming Kelps

The emerging sector of offshore kelp aquaculture represents an opportunity to produce biofuel feedstock to help meet growing energy demand. Giant kelp represents an attractive aquaculture crop due to its rapid growth and production, however precision farming over large scales is required to make this crop economically viable. These demands necessitate high frequency monitoring to ensure outplant success, maximum production, and optimum quality of harvested biomass, while the long distance from shore and large necessary scales of production makes in person monitoring impractical. Remote sensing offers a practical monitoring solution and nascent imaging technologies could be leveraged to provide daily products of the kelp canopy and subsurface structures over unprecedented spatial scales. Here, we evaluate the efficacy of remote sensing from satellites and aerial and underwater autonomous vehicles as potential monitoring platforms for offshore kelp aquaculture farms. Decadal-scale analyses of the Southern California Bight showed that high offshore summertime cloud cover restricts the ability of satellite sensors to provide high frequency direct monitoring of these farms. By contrast, daily monitoring of offshore farms using sensors mounted to aerial and underwater drones seems promising. Small Unoccupied Aircraft Systems (sUAS) carrying lightweight optical sensors can provide estimates of canopy area, density, and tissue nitrogen content on the time and space scales necessary for observing changes in this highly dynamic species. Underwater color imagery can be rapidly classified using deep learning models to identify kelp outplants on a longline farm and high acoustic returns of kelp pneumatocysts from side scan sonar imagery signal an ability to monitor the subsurface development of kelp fronds. Current sensing technologies can be used to develop additional machine learning and spectral algorithms to monitor outplant health and canopy macromolecular content, however future developments in vehicle and infrastructure technologies are necessary to reduce costs and transcend operational limitations for continuous deployment in an offshore setting.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1995

NASA Noise Reduction Program for Advanced Subsonic Transports

Aircraft noise is an important byproduct of the world's air transportation system. Because of growing public interest and sensitivity to noise, noise reduction technology is becoming increasingly important to the unconstrained growth and utilization of the air transportation system. Unless noise technology keeps pace with public demands, noise restrictions at the international, national and/or local levels may unduly constrain the growth and capacity of the system to serve the public. In recognition of the importance of noise technology to the future of air transportation as well as the viability and competitiveness of the aircraft that operate within the system, NASA, the FAA and the industry have developed noise reduction technology programs having application to virtually all classes of subsonic and supersonic aircraft envisioned to operate far into the 21st century. The purpose of this paper is to describe the scope and focus of the Advanced Subsonic Technology Noise Reduction program with emphasis on the advanced technologies that form the foundation of the program.

Stephens, David G.↗
NASA NTRS2001

Accurate Time-Dependent Traveling-Wave Tube Model Developed for Computational Bit-Error-Rate Testing

The phenomenal growth of the satellite communications industry has created a large demand for traveling-wave tubes (TWT's) operating with unprecedented specifications requiring the design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies on computational modeling. However, the TWT industry's computational modeling capabilities need to be improved because there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This limits the analysis and design of novel devices or TWT's with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. To address these concerns, a fully three-dimensional, time-dependent, helical TWT interaction model was developed using the electromagnetic particle-in-cell code MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm). The model includes a short section of helical slow-wave circuit with excitation fed by radiofrequency input/output couplers, and an electron beam contained by periodic permanent magnet focusing. A cutaway view of several turns of the three-dimensional helical slow-wave circuit with input/output couplers is shown. This has been shown to be more accurate than conventionally used two-dimensional models. The growth of the communications industry has also imposed a demand for increased data rates for the transmission of large volumes of data. To achieve increased data rates, complex modulation and multiple access techniques are employed requiring minimum distortion of the signal as it is passed through the TWT. Thus, intersymbol interference (ISI) becomes a major consideration, as well as suspected causes such as reflections within the TWT. To experimentally investigate effects of the physical TWT on ISI would be prohibitively expensive, as it would require manufacturing numerous amplifiers, in addition to acquiring the required digital hardware. As an alternative, the time-domain TWT interaction model developed here provides the capability to establish a computational test bench where ISI or bit error rate can be simulated as a function of TWT operating parameters and component geometries. Intermodulation products, harmonic generation, and backward waves can also be monitored with the model for similar correlations. The advancements in computational capabilities and corresponding potential improvements in TWT performance may prove to be the enabling technologies for realizing unprecedented data rates for near real time transmission of the increasingly larger volumes of data demanded by planned commercial and Government satellite communications applications. This work is in support of the Cross Enterprise Technology Development Program in Headquarters' Advanced Technology & Mission Studies Division and the Air Force Office of Scientific Research Small Business Technology Transfer programs.

Kory, Carol L.↗
DOE OSTI2023

No carbon storage in growth-limited trees in a semi-arid woodland

Plant survival depends on a balance between carbon supply and demand. When carbon supply becomes limited, plants buffer demand by using stored carbohydrates (sugar and starch). During drought, NSCs (non-structural carbohydrates) may accumulate if growth stops before photosynthesis. This expectation is pervasive, yet few studies have combined simultaneous measurements of drought, photosynthesis, growth, and carbon storage to test this. Using a field experiment with mature trees in a semi-arid woodland, we show that growth and photosynthesis slow in parallel as ψ pd declines, preventing carbon storage in two species of conifer (J. monosperma and P. edulis). During experimental drought, growth and photosynthesis were frequently co-limited. Our results point to an alternative perspective on how plants use carbon that views growth and photosynthesis as independent processes both regulated by water availability.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRSDate not supplied

Corridor Design and Analysis for UAM Operations

The Urban Air Mobility (UAM) concept is a part of Advanced Air Mobility (AAM), a joint initiative between the Federal Aviation Administration (FAA), NASA, and industry to develop an air transportation system that uses new electric (i.e., green) air vehicles in geographical areas previously underserved by traditional aviation. Market forecast studies predict that there will be demand for alternate modes of air transportation using electric Vertical Take-off and Landing aircraft. UAM expands transportation networks by introducing short flights to move people and goods around metropolitan areas​. UAM is expected to improve mobility for the public, decongest road traffic, reduce trip time, and decrease strain on existing public transportation networks. Various challenges exist to make the introduction of UAM operations successful in the U.S. National Airspace System (NAS). These include but are not limited to integration with existing airports and airspace, provision of air traffic services (e.g., separation), vehicle design and certification, and community acceptance. The focus of this paper is on integration of UAM operations into the NAS via introduction of new airspace structures. UAM will operate within a regulatory, operational, and technical environment that is incorporated into the NAS​. As per the UAM Concept of Operations (ConOps), the FAA retains regulatory authority and is responsible for establishing operational parameters and maintaining oversight. The FAA’s UAM ConOps describes flights at low altitudes (below 5,000 ft) with minimal disruption to established conventional aircraft traffic and limited voice interactions with the Air Traffic Control (ATC). Early stages of UAM may use existing procedures to safely integrate UAM with conventional flights. This would involve flying under Part 91 Visual Flight Rules (VFR) and using voice for communications. The initial UAM ecosystem will utilize the current infrastructure such as routes, helipads, and ATC services, where practicable. ​A NASA study explored the use of existing helicopter routes in Dallas Fort Worth (DFW) airspace for initial UAM operations with a Letter of Agreement (LOA) that included procedures to request a Class B (controlled airspace) clearance. The research showed that the chosen approach was feasible for near-term, low-demand UAM traffic, but was not scalable. The growth of operations in today’s aviation system has resulted in airspace reorganization and procedures to ensure safety and efficiency as traffic rates increase. One proposed operating innovation that can help with the scalability of UAM is establishing routes and corridors. This may look similar to the Area Navigation (RNAV) procedures used today to streamline operations into busy airports. However, instead of FAA automation systems and ATC managing the flow of traffic, some UAM concepts envision a third-party service provider performing this role as part of the Provider of Services for UAM (PSU) network. The FAA’s UAM ConOps posits that new airspace structures such as UAM corridors include the following design criteria: 1) Minimal impact on existing NAS operations, 2) no or minimal additional ATC services, 3) public interest considerations such as noise, safety, and security, and 4) customer needs. The airspace available in urban environments is limited by the height of buildings, the effect of weather including wind gusts, privacy needs, and a clearance envelope. The new airspace structure would need to be designed around large airports and urban areas where the initial market demand is likely to exist. NASA has started evaluating airspace in the Dallas Fort Worth area to design new airspace structures, keeping the first two design criteria in mind. It is assumed that there will be an on-board pilot-in-command, and the flights will operate under VFR in Visual Meteorological Conditions. Corridors will be required in controlled airspace, whereas UAM operations can fly in uncontrolled Class G and E airspace using current day rules. Keeler et. al identified factors and heuristics for development of routes for UAM operations for integration with airspace close to large airports such as Dallas Fort Worth and Dallas Love Field. This paper describes the heuristics applied to define the corridors, analyzes them with respect to legacy traffic and presents key results.

Urban Air Mobility↗
DOE OSTI2025

Glyceraldehyde-3-phosphate dehydrogenase homologs as bifunctional gatekeepers of metabolic segregation in Pseudomonas putida

Metabolically versatile Pseudomonas species can assimilate various glycolytic and gluconeogenic substrates. Simultaneous assimilation is known to segregate carbons from each substrate type into different metabolic pathways. However, the mechanisms of this metabolic segregation remain unresolved. Here, we investigate Pseudomonas putida KT2440 during processing of the sugar glucose through glycolysis versus the phenolic acid ferulate through gluconeogenesis. Metabolome profiling reveals up to twofold less tricarboxylic acid cycle metabolites but up to 10-fold higher metabolites of upper glycolysis, pentose-phosphate, and Entner–Doudoroff pathways in glucose-grown cells compared to ferulate-grown cells. After 13C-substrate switching, kinetic isotopic profiling captures rapid assimilation of new substrate carbons into initial catabolic pathways, but incorporation into downstream pathways is absent or incomplete. Proteomics identifies a 22-fold higher abundance of one homolog of glyceraldehyde-3-phosphate dehydrogenase (GAPDH, GapA) in cells fed on glucose relative to ferulate, while abundance of another homolog (GapB) remains unchanged. Growth phenotypes and quantitative metabolomics for single and double knockout mutants of these GAPDH homologs indicate only GapA involvement in glycolytic flux, which can be compensated by the Entner–Doudoroff pathway, and distinct preference of GapB with minimal role of GapA for gluconeogenic flux. Accordingly, growth of triple knockout mutant with deletion of gapA, gapB, and edd is possible only when glycolytic and gluconeogenic substrates are provided together to meet metabolic demands in a segregated fashion, but metabolic tradeoffs lead to slow growth. A mathematical, experimentally constrained, model of the GAPDH node shows that tuning of GapA and GapB concentrations enables transition between flux regimes for nutritional adaptability.

Zhou, Nanqing [Northwestern University, Evanston]↗
DOE OSTI2020

Exploiting nonionic surfactants to enhance fatty alcohol production in Rhodosporidium toruloides

Fatty alcohols (FOHs) are important feedstocks in the chemical industry to produce detergents, cosmetics, and lubricants. Microbial production of FOHs has become an attractive alternative to production in plants and animals due to growing energy demands and environmental concerns. However, inhibition of cell growth caused by intracellular FOH accumulation is one major issue that limits FOH titers in microbial hosts. In addition, identification of FOH-specific exporters remains a challenge and previous studies towards this end are limited. To alleviate the toxicity issue, we exploited nonionic surfactants to promote the export of FOHs in Rhodosporidium toruloides, an oleaginous yeast that is considered an attractive next-generation host for the production of fatty acid-derived chemicals. Our results showed FOH export efficiency was dramatically improved and the growth inhibition was alleviated in the presence of small amounts of tergitol and other surfactants. As a result, FOH titers increase by 4.3-fold at bench scale to 352.6 mg/L. With further process optimization in a 2-L bioreactor, the titer was further increased to 1.6 g/L. The method we show here can potentially be applied to other microbial hosts and may facilitate the commercialization of microbial FOH production.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Metal additively manufactured wavy fin cold-plate architecture for improved thermal-hydraulic performance

Rapid growth in artificial intelligence and data center workloads demands high-performance liquid cooling to manage increasing chip power. This study presents two metal-additive-manufactured cold plates with sinusoidal fins, constant-amplitude wavy fins and linearly variable-amplitude wavy fins and compares them against metal-additive-manufactured straight fins using experiments conducted at 1 kW heat dissipation as well as high-fidelity 3D conjugate computational fluid dynamic simulations. The cold plates were printed in AlSi10Mg material and underwent design using a Python-automated workflow prior to manufacture and testing. The experiments show that wavy fins reduce the normalized thermal resistance by 35 to 45 % at water flow rates from 1 to 4 LPM. At a fixed 20 kPa pressure drop, the variable-waviness design lowered peak surface temperature by 9 °C and thermal resistance by 51 %, while edge-channel maldistribution in the constant wavy fin design limited gains. A thermal resistance breakdown revealed that 55–63 % of the total thermal resistance in wavy designs comes from base heat conduction, 27–33 % from fin heat conduction, and 9–13 % from fin heat convection, indicating the need to address conduction bottlenecks. Parametric sweeps identify a 3 mm fin pitch as optimal, and that horizontal inlet/outlet manifolds further reduce pressure drop by 30–60 % and thermal resistance by 9–16 % relative to vertical inlet-outlet manifolds. The results yield comprehensive guidelines for fin geometry, manifold alignment, material selection and additive-manufacturing constraints to realize high-performance liquid-cooled cold plates for power-dense electronics.

3d printing↗