Thermal management system and method

An assembly, comprising:

• a plurality of monolithic foil structures, each of the monolithic foil structures having a body with opposite external and internal surfaces that, respectively, form an asymmetric outer profile relative to a cross-sectional plane and a symmetric internal conduit relative to the cross-sectional plane, the outer profile and the internal conduit having different shapes, the internal surface of the body extending from an inlet end of the body to an opposite outlet end of the body, the internal surface being rounded at an interface between the internal surface and each of the inlet end and the outlet end, the body also including fins projecting from the external surface of the body with the fins of a first monolithic foil structure of the monolithic foil structures disposed crossing over and above the fins of a second monolithic foil structure of the monolithic foil structures relative to the cross-sectional plane, the first monolithic foil structure located adjacent to the second monolithic foil structure, the body configured to physically isolate a first fluid flowing along the external surface from a second fluid flowing in the internal conduit, the body configured to transfer thermal energy between the first fluid flowing along external surface and the second fluid flowing in the internal conduit.

A method, comprising:

• forming a first layer of material on a build platform;
• and
• forming one or more additional, second layers of the material above the first layer to additively manufacture a monolithic foil structure having a body with opposite external and internal surfaces that, respectively, form an outer profile and an internal conduit having different shapes, the shape of the outer profile being asymmetric on opposite sides of a cross-sectional plane extending along a length of the internal conduit, the shape of the internal conduit being symmetric on the opposite sides of the cross-sectional plane, the internal conduit extending from an inlet end to an outlet end with the internal surface being rounded at an intersection between the internal surface and each of the inlet end and the outlet end, the body including fins projecting from the body at non-orthogonal angles, wherein the monolithic foil structure is configured to physically isolate a first fluid flowing along the external surface from a second fluid flowing in the internal conduit while transferring thermal energy between the first fluid and the second fluid.