ANR project

Development of Thermoelectric Legswith 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)

Partner laboratories:

  • CIRIMAT (UMR 5085 CNRS/University of Toulouse 3)
  • CRISMAT (UMR 6508 CNRS/University of Caen Normandy, ENSICAEN)
  • IMN (UMR 6502 CNRS/University of Nantes)

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

Fabrication of 3D Thermoelectric Legs (LEGs) Using Binder Jetting Coupled with Spark Plasma Sintering: Impact of Fabrication Parameters Through to Module Assembly

Thermoelectric (TE) compounds can convert waste heat into useful electrical energy (energy recovery) when formed into components called legs (or LEGs). It is necessary to reduce the production cost and manufacturing time of these LEGs. In addition, certain additional challenges are emerging, such as reducing raw material waste and producing complex shapes.
Increasing the integration of TE devices and enhancing their TE conversion efficiency are also, to date, clearly identified challenges.
The project aims to study the technical feasibility of manufacturing these LEGs with optimized properties using an innovative method: additive manufacturing via binder jetting coupled with a sintering step.
Indeed, this approach would enable the design of complex shapes conducive to improved energy conversion. The efficiency of thermoelectric devices would thus be increased. Their integration into existing systems would then be facilitated, ensuring that the desired performance requirements are met.
Proof-of-concept demonstrations have already been carried out by the project leader, including the assembly of a complete module. In this project, we will study two families of TE materials: silicides and chalcogenides.
This project will focus on several areas:
*the impact of fabrication parameters and their optimization using Bayesian methods (AI)
*the effects of powder characteristics on the elemental, structural, microstructural, and mechanical properties
*the electrical and thermal transport properties of these materials
The goal of the project is to achieve the best TE properties and to provide a deeper understanding of the impact of fabrication parameters on the performance of LEGs, through the analysis of the resulting microstructures.

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