A method of producing a complex product includes designing a three dimensional preform of the complex product, creating a three dimensional preform of the complex product using the model, depositing a material on the preform, and removing the preform to complete the complex product. In one embodiment the system provides a complex heat sink that can be used in heat dissipation in power electronics, light emitting diodes, and microchips.

A heat sink includes a lower shell, an upper shell, and an internal matrix having a space. The space is configured to receive a phase change material. The lower shell, the upper shell and the internal matrix are formed as a single component using additive manufacturing techniques. The upper shell can include a fill port and a vent port. The fill port can be configured to provide a path into the space of the internal matrix for the phase change material. The fill port and the vent port can each be configured to receive a seal plug, such as an expansion plug.

Exfoliated graphite materials, and composite materials including exfoliated graphite, having enhanced through-plane thermal conductivity can be used in thermal management applications and devices. Methods for making such materials and devices involve processing exfoliated graphite materials such as flexible graphite to orient or re-orient the graphite flakes in one or more regions of the material.

Methods and apparatus for processing flexible graphite sheet material involve patterning the material, on at least one major surface, prior to further processing of the material such as densification, lamination, folding or shaping into three-dimensional structures. For densification and lamination, the patterning is selected to facilitate the removal of air from the flexible graphite sheet material during the densification and lamination process. For folding or shaping, the patterning is selected to render the graphite sheet material more flexible. In some embodiments, methods for increasing the through-plane conductivity of flexible graphite sheet material are employed. Integrated heat removal devices include sheets of graphite material that have been selectively patterned in different regions to impart desirable localized properties to the material prior to it being shaped or formed into an integrated heat removal device. Coatings and/or resin impregnation can also be used to impart desirable properties to the material or device.

A method of manufacturing a heat dissipation device is disclosed. The heat dissipation device manufactured with the method includes two titanium metal sheets, which are subjected to a heat treatment before undergoing mechanical processing, plastic working and surface modification. With these arrangements, the titanium metal sheets can be freely plastically deformed and possess a capillary force, and can therefore be used in place of the conventional copper material to serve as a material for making heat dissipation devices, and the heat dissipation devices so produced can have largely reduced weight and largely improved heat dissipation performance.

A method of fabricating a liquid-cooled heat sink assembly, including: providing a heat transfer element including a heat transfer base having opposite first and second sides, and a plurality of thermally conductive fins extending from the first side of the heat transfer base, the second side of the heat transfer base to couple to a component(s) to be cooled; providing a coolant-carrying structure including a coolant-carrying base and a coolant-carrying compartment through which liquid coolant flows, the coolant-carrying base including a plurality of fin-receiving openings sized and positioned for the plurality of thermally conductive fins of the heat sink base to extend through; and attaching the heat transfer element and coolant-carrying structure together with the plurality of thermally conductive fins extending through the fin-receiving openings in the coolant-carrying base into the coolant-carrying compartment.

A manufacturing method of heat dissipation unit is disclosed. The heat dissipation unit is mainly composed of two titanium metal plate bodies. The titanium metal plate bodies are heat-treated, whereby the titanium metal plate bodies can be mechanical processed, shaped and surface-modified. Accordingly, the titanium metal can be freely shaped and provide capillary attraction. In this case, the titanium metal plate bodies can be used as the material of the heat dissipation unit instead of the conventional copper plate bodies to greatly reduce the weight and enhance the heat dissipation performance.

An exterior aircraft light unit comprises a housing, at least one light source, and a heat sink. The heat sink includes at least one first heat sink portion and at least one second heat sink portion. The at least one light source is thermal connected with the at least one first heat sink portion for transferring heat from the at least one light source to the at least one first heat sink portion; and the at least one second heat sink portion is configured to be selectively attachable to the at least one first heat sink portion.

A heat sink is provided that includes a lower shell, an upper shell and an internal matrix. The lower shell, the upper shell and the internal matrix are formed as a single component using additive manufacturing techniques. The internal matrix includes a space that is configured to receive a phase change material.

A method of manufacturing a liquid-cooled jacket, includes: a placing step for placing a sealing body on a jacket body; a first primary joining step for performing frictional stirring by moving a primary joining rotary tool along a first abutment portion where a step side surface of a peripheral wall stepped portion and an outer peripheral side surface of the sealing body abut on each other; and a second primary joining step for performing frictional stirring by moving the primary joining rotary tool along second abutment portions in each of which a step side surface of a columnar support stepped portion and a hole wall of a hole abut on each other.