Multi-Objective Optimization of Triply Periodic Minimal Surface (TPMS)-Based Heat Sink for Power Electronics in Energy Systems

Efficient thermal management is essential for power electronic systems in renewable energy applications, where excessive heat can compromise performance and reliability. This study investigates the use of Triply Periodic Minimal Surface (TPMS) structures for heat sink design, with a focus on performance enhancement through geometric optimization. Six distinct TPMS topologies were analyzed using computational fluid dynamics (CFD) and thermal simulations. Among them, the Gyroid structure demonstrated the highest performance index, attributed to its low thermal resistance, reduced pressure drops (1 4.1 P a), lightweight nature, and high surface area-to-volume ratio. To further improve its performance, the Gyroid geometry was optimized by varying cell size, thickness, and directional anisotropy. Results showed that reducing cell size and introducing directional variation (vertical fin orientation) significantly decreased thermal resistance. Mechanical analysis confirmed the structural integrity of the optimized design, with a maximum von Mises thermal stress of 139 MPa and a peak deformation of only 0.15 mm. These findings validate the Gyroid TPMS structure as a superior candidate for advanced, lightweight heat sinks in power electronics, integrating thermal performance with mechanical robustness for next-generation renewable energy systems.