AccScience Publishing / ESAM / Online First / DOI: 10.36922/ESAM025260016
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REVIEW ARTICLE

Recent advances in thermal management via additive manufacturing

Sooyeon Ji1 ,  Junyeol Choi1 ,  Myounggi Hong1 ,  Jeongwoo Lee1 ,  Yong Choi1 ,  Jiheon Kim1 ,  Jaemin Lee1* ,  Wonjoon Choi1*
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1 School of Mechanical Engineering, Korea University, Seongbuk-Gu, Seoul, Republic of Korea
ESAM, 025260016 https://doi.org/10.36922/ESAM025260016
Received: 24 June 2025 | Revised: 22 July 2025 | Accepted: 28 July 2025 | Published online: 18 August 2025
© 2025 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Additive manufacturing (AM) has emerged as a transformative approach for advancing thermal management technologies, providing unprecedented freedom in design, material customization, and the implementation of novel thermal control strategies. This review presents a comprehensive overview of recent progress in AM-enabled thermal management, with an emphasis on enhancements in conductive, convective, boiling, and radiative heat transfer. AM facilitates the fabrication of complex architectures and composite materials with tailored thermal conductivities, substantially improving heat dissipation in diverse applications, including electronics, automotive systems, aerospace structures, and building technologies. Notably, recent developments in thermal metamaterials—such as structures capable of thermal cloaking and directional heat conduction—highlight the considerable potential of AM for manipulating complex thermal fields. Furthermore, the integration of phase change materials within AM-fabricated structures offers improved energy storage capacity and efficient thermal regulation. Future research should focus on the development of advanced composite materials, the integration of artificial intelligence for design optimization, the exploration of multifunctional metamaterials, and the advancement of sustainable and scalable AM processes. Hybrid and multimaterial AM techniques are particularly promising, enabling the fabrication of complex, functionally graded structures with precisely tailored thermal and mechanical properties. Addressing critical challenges—including structural integrity, microstructural control, material scalability, cost-effective production, and environmental sustainability—will further strengthen the role of AM in thermal management. In addition, the continued incorporation of high-fidelity computational simulations and real-time monitoring into AM workflows is expected to enhance process reliability and reproducibility. Expanding the range of AM applications to encompass lightweight and optically transparent polymer-based devices could unlock new avenues for thermal management in sensitive electronic and photonic systems.

Keywords
Thermal management
Conduction heat transfer
Convection heat transfer
Boiling heat transfer
Radiative cooling
Phase change material
Thermal metamaterial
Funding
This work was supported by an Agency for Defense Development of Korea (ADD) grant (915050201), National Research Foundation of Korea (NRF) funded by the Korean government (Ministry of Science and ICT) (2023R1A2C2006407, 2020R1A5A1018153), and Korea Evaluation Institute of Industrial Technology (KEIT) grant funded by the Korea government (MOTIE) (No. RS-2024- 00433288).
Conflict of interest
Wonjoon Choi is an Editorial Board Member of this journal, but was not in any way involved in the editorial and peer-review process conducted for this paper, directly or indirectly. Separately, other authors declared that they have no known competing financial interests or personal relationships that could have influenced the work reported in this paper.
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Engineering Science in Additive Manufacturing, Electronic ISSN: 3082-849X Published by AccScience Publishing
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