Systems and methods for using additive manufacturing for thermal management

A thermal management system, comprising:

• a hollow vapor chamber containing a working fluid that conducts heat from a heat source to a cold reservoir, the hollow vapor chamber having an interior defining a vapor space to contain a vapor of the working fluid and having a non-porous exterior wall and a porous wick structure integrally formed with the non-porous exterior wall by an additive manufacturing process, the porous wick structure being in the interior of the hollow vapor chamber, wherein
• the non-porous exterior wall has a component side surface thermally coupled to a heat generating component of the heat source, the component side surface having a shape that at least partially conforms to at least one surface of the heat generating component, and
• a portion of the porous wick structure opposite the component side surface of the non-porous exterior wall directs the working fluid toward the heat generating component,
• wherein the hollow vapor chamber comprises straight integrally formed internal support posts formed by the additive manufacturing process that extend at an angle between opposing sides of the hollow vapor chamber, the internal support posts having a truss structure.