Geometric Design and 3D Printing of Thermoelectric Materials and Devices

Heat is omnipresent in natural and artificial environments, more than 60% of which is dissipated. Thermoelectric (TE) power generation can provide a unique solution to convert this dissipated, wasted heat into useful energy, that is, electricity. The performance of thermoelectric modules, typically composed of cuboid-shaped materials, depends on both the materials’ intrinsic properties and the temperature difference created. Despite significant advancements in the development of efficient materials, macroscopic thermal designs capable of accommodating larger temperature differences have been largely underexplored because of the challenges associated with processing bulk thermoelectric materials. At this moment, three-dimensional (3D) printing technology can maximize the flexibility in the design and fabrication of TE modules into more efficient structures. Herein, we present the design strategy for various thermoelectric materials for enhancing power generation performances using a combination of finite element modeling and 3D printing. The macroscopic geometries are designed and realized by the 3D printing processes, leading to significant enhancements in the temperature difference within devices and the resulting output powers. The proposed approach paves the way for designing efficient thermoelectric power generators.