Current Developments in the Use of FDM 3D-Printed Materials for Efficient Heat Transfer Applications

This work investigates the potential of additive manufacturing (AM) technologies for prototyping and developing functional components in thermal systems, with particular emphasis on thermal and mechanical performance. The study focuses on two complementary prototyping strategies: (i) the use of metal-filled polymer filaments in Fused Deposition Modeling (FDM), also known as Material Extrusion (MEX) according to ISO/ASTM 52900:2022, and (ii) a hybrid approach combining polymer 3D printing with conductive coating and electrochemical copper deposition. While metal-filled filaments provide a rapid and low-cost solution for early-stage prototyping, their mechanical properties remain similar to those of the polymer matrix, limiting their applicability in load-bearing structures. In contrast, the hybrid method enables the fabrication of hollow metallic geometries with improved thermal and electrical conductivity. This approach is more time-consuming and process-intensive and is therefore considered a subsequent stage in the prototyping workflow following initial MEX-based design iterations. Compared with conventional polymer-based MEX, several AM approaches enable the development and fabrication of fully metallic or metal-functional structures, including Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and hybrid polymer–metal methods based on electroplating. Furthermore, understanding mechanical properties such as tensile strength is essential for assessing the applicability of AM materials in energy system components. The results contribute to bridging the gap between rapid prototyping and the implementation of advanced AM technologies in thermal-related applications.