3D structures and methods therefor

A The method of forming a heat exchanger, the method comprising:

• forming a first stacked layer by depositing a thermally conductive continuous bead of material along an uninterrupted path that defines a first layer of a three-dimensional (3D) structure;
• and
• forming a sidewall of the 3D structure having opposing surfaces respectively defined by the first stacked layer and one or more successive stacked layers of the 3D structure by, for each successive stacked layer, continuing depositing the continuous bead of material uninterruptedly from the first stacked layer along the path and with a surface thereof in contact with a surface of the continuous bead of material of an adjacent one of the stacked layers, including stacking the layers with an offset relative to each other to define a conical portion of the sidewall, the conical portion having a base and an apex that are disposed laterally relative to one another in a direction along one of the stacked layers.

A heat exchanger apparatus comprising:

• a first stacked layer of a continuous bead of material extending along a path that defines a first layer of a three-dimensional (3D) structure;
• and
• a sidewall of the 3D structure having opposing surfaces respectively defined by the first stacked layer and successive stacked layers of the 3D structure, each stacked layer including a portion of the continuous bead of material that extends uninterruptedly from the first stacked layer and through the successive stacked layers, along the path and with a surface thereof in contact with a surface of the continuous bead of material of an adjacent one of the stacked layers, the continuous bead of material that extends uninterruptedly forming the heat exchanger with the stacked layers being offset relative to one another to define a conical recessed portion of the sidewall, the sidewall being configured for exchanging heat between respective fluids passing on opposing surfaces of the sidewall while maintaining the fluids separate from one another.

A method of 3D-printing, the method comprising:

• forming a conductive polymer-based material by dispersing a plurality of metal-based flakes in a polymer,
• forming a 3D structure by extruding the conductive polymer-based material from a nozzle along a continuous path and uninterruptedly depositing the extruded material as an uninterrupted continuous bead that extends uninterruptedly through respective layers of the 3D structure and forms a heat exchanger including stacked layers offset relative to one another that define a conical recessed portion of a sidewall.