ANR project

Development of Thermelectric Legs with Complex 3D Geometry Using a Binder Jetting Process Coupled with Spark Plasma Sintering: Impact of Manufacturing Parameters, Through to the Assembly of Prototype Modules

Dates:

Starting 2026 – Ending 2030

Coordinator Laboratory of the project: CIRIMAT (UMR 5085 CNRS/University of Toulouse 3, Y. THIMONT)

IMN Coordinator of the project:: David BERTHEBAUD, MIOPS team

Partner laboratories:

  • CIRIMAT (UMR 5085 CNRS/Université de Toulouse 3)
  • CRISMAT (UMR 6508 CNRS/Université de Caen Normandie, ENSICAEN)
  • IMN (UMR 6502 CNRS/Nantes Université)

Persons of IMN involved:
David BERTHEBAUD (CR CNRS), Olivier HERNANDEZ (Professor), Pierre-Emmanuel PETIT (IR CNRS)

Elaboration of THERMOelectric LEGs with 3D complex geometry by binder jetting coupled to spark plasma sintering route: Impact of manufacturing parameters, up to the assembly of modules prototypes

ThermoElectric compounds (TE) allow for the conversion of waste thermal energy into useful electrical energy (Energy harvesting) when they are put in the form of parts called legs.
It is necessary to reduce the production cost and manufacturing time of these legs.
In addition, certain additional challenges are emerging, such as minimizing material loss, as well as the ability to create legs with complex shapes to increase the TE devices integration and conversion efficiency.
The project will focus on the optimized legs elaboration feasibility by Binder Jetting (BJ) additive manufacturing route coupled to Spark Plasma Sintering step.
Indeed, the use of this route would make it possible to assign them complex shapes favorable to energy conversion, increasing the efficiency of TE devices and also facilitating their integration while satisfying the desired needs.
The first investigations carried out by the project leader demonstrated the first proofs of concept of the use of this innovative elaboration route until to the module assemblage.
In this project, we will study two families of TE materials: Silicide and Chalcogenides.
This project will focus on several areas:
*the impact of fabrication parameters and their optimization using Bayesian methods (AI)
*the influence of powder characteristics on elemental, structural, microstructural, and mechanical properties
*the electrical and thermal transport properties of these materials
The ultimate goal of the project is to achieve the best TE properties and to provide a deeper understanding of how fabrication parameters affect the performance of legs, through analysis of the resulting microstructures.

Figure: Manufacture of thermoelectric legs using binder jetting (a) combined with Spark Plasma sintering (b)