This study investigates the potential of Laser Powder Bed Fusion (LPBF) for the design of innovative porous AlSi10Mg structures for heat pipe applications. The internal structure of the capillary wick is crucial for balancing capillary pumping and permeability, areas where conventional technologies fall short. By varying hatch distance, linear energy density, and inter-layer rotation angles, we generated controlled porous networks. Two experimental setups — Forced Fluid Flow and capillary RateOf-Rise — were designed and built to measure the permeability and the capillary performance of the porous structures. Micro-computed tomography enabled detailed porosity computations and correlation with numerical
simulations. Optimal results were achieved with porosity between 55% and 65%, and a 90° inter-layer rotation angle. This work highlights the potential of additive manufacturing in optimizing wick design for functional heat pipes.

Keywords: Porous structures; Capillary Performances; Laser Powder Bed Fusion; Tomography