What is it about?
Flexible heat exchangers with intricate three-dimensional (3D) geometries exhibit superior mechanical and thermal performance compared with traditional two-dimensional (2D) designs. Their ability to offer greater design freedom and unique functionalities makes them particularly attractive for wearable medical devices. This study investigates flexible heat exchanger technologies in three main directions: (i) miniaturisation, (ii) integration of physical and mathematical models, and (iii) enhanced adaptability through heterogeneous design integration. Through a combination of literature review, mathematical modelling, and experimental analysis, the thermal efficiency of several configurations is compared, including basic thermoplastic polyurethane (TPU) tubes and 3D bio-inspired TPU tubes with aluminium-finned structures. The findings establish a foundation for the development of next-generation flexible wearable medical cooling devices with improved thermal management capabilities and practical applicability in industrial design. Furthermore, the outcomes of this research will directly support the development of improved wearable cooling devices within a UK-based medical device SME, Paxman Scalp Coolers, facilitating the translation of advanced heat exchanger designs into clinically relevant and commercially viable solutions.
Featured Image
Why is it important?
Wearable devices with integrated heat exchangers have gained significant attention due to their potential to provide personalised thermal management in medical, sports, and industrial applications.
Perspectives
A key consideration in the development of tubular heat exchangers for wearable devices is the selection of appropriate materials. Thermoplastic polyurethane (TPU) and silicone are the most used materials due to their excellent flexibility, durability, and chemical resistance. These properties are crucial for ensuring longevity, comfort, and safety in wearable applications. Their ability to withstand mechanical deformation under varying environmental conditions further supports their use in such systems. However, their relatively low thermal conductivity can limit heat transfer efficiency. The effectiveness of tubular heat exchangers in wearable designs largely depends on their ability to maintain efficient heat transfer while remaining comfortable and unobtrusive. Optimising the fluid flow rate, tube dimensions, and overall geometry can significantly improve thermal performance. Recent research has focused on improving thermal performance by integrating high conductivity materials such as graphene and aerogels, which enhance HT while maintaining the lightweight and flexible characteristics required for wearables. In parallel, 3D printing technologies have enabled the creation of intricate microchannel designs within tubes, providing greater control over fluid flow and improved heat dissipation
Prof. Dr. Necdet Geren
University of Çukurova
Read the Original
This page is a summary of: A Bio-Inspired Approach to Flexible Tubular Heat Exchanger Design for Wearable Medical Technology, Applied Sciences, April 2026, MDPI AG,
DOI: 10.3390/app16094112.
You can read the full text:
Contributors
The following have contributed to this page
