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LED lights are energy-efficient lighting devices that emit light when an electrical current passes through a semiconductor. They are known for their low energy consumption and longer lifespan when protected from exposure to high temperatures through the use, for example, of heat sinks.
Heat sinks are engineered to dissipate the heat generated by the lightbulb, keeping the LED cool and ensuring optimal operation and longevity. Traditional heat sinks are manufactured out of aluminum, a relatively heavy and expensive material. Achieving the same performance with a different material has therefore the potential to lower manufacturing costs and increase the lifespan of the LED light.
ColdStream helps thermal engineers build more efficient heat sinks by optimizing them through generative design, improving heat dissipation and reducing material usage.
As a leader in LED lighting, Avient faced two challenges: improving the thermal performance of their LED modules and reducing the weight of these components. Traditionally, aluminum heat sinks have been the go-to solution due to their excellent thermal conductivity. However, aluminum's weight and cost led Avient to seek a lighter, more cost-effective alternative using thermally conductive plastics on the condition that it would not compromise thermal performance. Avient used ColdStream to solve these problems.
As a first step in the redesign of their products, Avient needed to build and calibrate the thermal model within ColdStream. The main model parameters, such as the calibration output of thermal power and LED material properties, were either readily available, or determined by experiment by the Avient team prior to the start of the project. The experiments that were conducted immediately provided them with a benchmark that they used to successfully validate the ColdStream analyses. With a validated model, the Avient team used ColdStream to generate various heat sink designs based on specific criteria: they had to be injection moldable, minimize volume, and optimize thermal performance by lowering temperatures across the design.
Avient employed two generative design methodologies offered by ColdStream: standard design generation and topology optimization. The standard design runs produced approximately 60 design options, focusing on standard shapes like fins and pins. Topology optimization yielded a single, highly optimized design that incorporated specific shapes to maximize thermal efficiency.
After generating the designs, the team compared them against the baseline aluminum design, whose thermal performance enabled a PCB temperature of 55°C. The same design made in thermally conductive plastic achieved a 42% weight reduction with only a 5°C increase in temperature compared to aluminum. The following designs were generated by ColdStream:
Avient then prototyped the most promising designs using a layer-by-layer deposition process to produce parts from thermally conductive plastic. These prototypes' performances matched the simulation results with a margin of error below 15%—an exceptional range given the differences between 3D-printed and injected parts.
This case study underscores the potential of thermallyconductive plastics as a viable alternative to aluminum in LED applications. By combining the use of ColdStream with prototyping, Avient developed new product solutions that reduced product weight up to 82% and enhanced thermal performance up to 32%.
Avient is a leading provider of specialized polymer materials and solutions designed to enhance the performance and sustainability of products across various industries. They offer a wide range of services such as custom polymer formulations, color and additive systems, and packaging solutions. Avient is committed to environmental stewardship, focusing on reducing energy consumption, minimizing the use of non-renewable resources, and increasing the use of recycled materials. Their global network of experts ensures compliance with regulations in multiple sectors, including healthcare, packaging, and consumer goods. Avient’s dedication to innovation and collaboration makes them a trusted partner for companies seeking to improve product performance and sustainability.
