Vortex-enhanced jet impingement and the role of impulse generation rate in heat removal using additively manufactured synthetic jet devices

This article presents an approach to the design and fabrication of synthetic jet devices (SJDs) using rapid prototyping via additive manufacturing, marking the first study to employ this method for such devices. This manufacturing technique empowers researchers with complete design freedom, enabling the production of ultra-thin SJDs—as thin as 4  mm—without mechanical fasteners and facilitating the rapid fabrication of multiple devices with varying geometries. To showcase the potential of this method, SJDs with conical and cylindrical cavities and orifices ranging from 1.6  mm to 7  mm were designed, fabricated, and tested.

These devices achieved air jet exit velocities exceeding 106  m/s using a single piezoelectric diaphragm—among the highest reported in the literature—validating the effectiveness of this manufacturing approach. This high jet velocity is significant for practical applications requiring efficient thermal management, such as cooling high-power-density electronics, where compact and energy-efficient solutions are essential. Beyond achieving high velocities, it was revealed that maximizing jet velocity alone is not always optimal for heat removal. The hydrodynamic impulse generation rate was introduced as a more significant factor influencing heat transfer performance. By fabricating and testing multiple SJDs with different geometries, it was demonstrated that the impulse generation rate, which accounts for both jet velocity and flow rate, better correlates with enhanced heat transfer capabilities than jet velocity alone. This insight addresses an often-overlooked parameter in SJD design and has substantial implications for optimizing heat removal performance. Moreover, lumped element modeling, tuned solely on diaphragm deflection behavior, accurately predicted device performance and was validated using a hotwire anemometer. This model effectively characterizes center-axis orifice devices and confirms its applicability to thin-cavity designs, providing a valuable tool for future SJD development. Despite moderate volume flow rates (0.2 to 0.8  m³/h), the fabricated SJDs delivered significant improvements in heat transfer. Compared to natural convection, these devices achieved over 13 times greater heat removal rates, with an average heat transfer coefficient exceeding 120  W/m²·K over a 30  mm × 30  mm heated surface. These findings demonstrate the practicality and effectiveness of vortex-enhanced synthetic jet impingement for targeted and efficient cooling of localized hot spots. This approach offers multiple advantages over traditional rotary cooling systems like fans, including increased reliability, lower profile, while consuming less than 100 mW. The ability to rapidly prototype and optimize SJDs using additive manufacturing accelerates research and development in this field, paving the way for advanced thermal management solutions in real-world applications.