Democratising Engineering Education: Fabrication and Experimental Validation of a Low-Cost FDM 3D-Printed Metal-Composite Plate Heat Exchanger

Héctor de Paz Carmona; Rubén Díaz López; Óscar García-Afonso

doi:10.3991/ijep.v16i3.60829

Authors

Héctor de Paz Carmona Universidad de La Laguna (ULL), La Laguna (Tenerife), Spain https://orcid.org/0000-0002-8849-0977
Rubén Díaz López Universidad de La Laguna (ULL), La Laguna (Tenerife), Spain
Óscar García-Afonso Universidad de La Laguna (ULL), La Laguna (Tenerife), Spain https://orcid.org/0000-0002-0946-1853

DOI:

https://doi.org/10.3991/ijep.v16i3.60829

Keywords:

Chemical engineering education, additive manufacturing, Active learning, Metal-polymer filaments, Low-cost Laboratories

Abstract

Heat exchange is a key part of the current chemical and mechanical engineering curriculums at the university. However, students often see it as abstract because of the ‘black box’ nature of commercial heat exchangers in industry and the high cost of laboratory pilot plants for learning. This manuscript introduces an innovative educational project focused on the design, 3D-printing, and experimental testing of a plate heat exchanger (PHE). To overcome the low thermal conductivity of standard PLA for FDM printing, a high-metal-composite filament (>60% bronze-filled) was used, which allowed for much more efficient heat exchange. The project, conducted by a chemical engineering undergraduate student, consisted of an initial screening of open-source 3D models of heat exchangers, followed by fused deposition modelling 3D printing using different filaments and technical validation. The experimental testing was performed using tap water at 60ºC and 20ºC to determine the overall heat transfer coefficient. Our results indicate that 3D-printed PHEs show a significant thermal performance, providing a low-cost alternative to commercial units or expensive learning units. To the best of authors’ knowledge, this approach goes beyond technology. This offers a practical way to update and democratize engineering laboratories while increasing student engagement through hands-on challenges.

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