Evaluation and improvement of the thermal performance of power modules using the Finite-Element-Method (FEM) and Multi-Material Additive Manufacturing (MMAM)

Lehmann CL, Utsch D, Sprenger M, Thielen N, Franke J, Risch F, Schulze V, Zanger F (2026)

Publication Type: Conference contribution

Publication year: 2026

Original Authors: Chantal-Liv Lehmann, Daniel Utsch, Mario Sprenger, Nils Thielen, Jörg Franke, Florian Risch, Volker Schulze, Frederik Zanger

Event location: Amberg DE

DOI: 10.1109/MIDCongress66428.2025.11547395

Abstract

Mechatronic Integrated Devices (MID) for high temperature and harsh environments include power electronic applications. There is a growing need for innovative packaging concepts that enhance thermal performance, and reliability while offering greater manufacturing efficiency. This work proposes a novel approach that combines the evaluation of thermal and thermo-mechanical performance of various innovative designs using numerical simulations with the design freedom of the additive manufacturing technology Vat Photopolymerization (VPP), including an advanced multi-material process with ceramic and metallic slurries. It can be found that the thermal performance is reduced by 16% using aluminum nitride as ceramic material and innovative comprised module designs, which can be demonstrated by thermal simulations and printed by VPP in one single machine.

Authors with CRIS profile

Daniel Utsch Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Mario Sprenger Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Nils Thielen Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Jörg Franke Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Florian Risch Professur für Montagetechnologien elektrischer Energiespeicher

Involved external institutions

Karlsruhe Institute of Technology (KIT) DE Germany (DE)

How to cite

APA:

Lehmann, C.-L., Utsch, D., Sprenger, M., Thielen, N., Franke, J., Risch, F.,... Zanger, F. (2025). Evaluation and improvement of the thermal performance of power modules using the Finite-Element-Method (FEM) and Multi-Material Additive Manufacturing (MMAM). In Proceedings of the 2025 16th International MID Congress Mechatronic Integration Discourse (MID Congress). Amberg, DE.

MLA:

Lehmann, Chantal-Liv , et al. "Evaluation and improvement of the thermal performance of power modules using the Finite-Element-Method (FEM) and Multi-Material Additive Manufacturing (MMAM)." Proceedings of the 2025 16th International MID Congress Mechatronic Integration Discourse (MID Congress), Amberg 2025.

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