Attaining Tailored Wicking Behavior with Additive Manufacturing

Additive manufacturing (AM) has opened a new pathway to create customized wicking materials. With lower manufacturing costs and a larger design space than many alternatives for wicking, AM is of particular value in fields such as thermal management and microfluidics. Fluid propagation during wicking in porous media, however, has largely remained limited to Washburnian ($$) behavior, and optimizing these materials for wicking in a variety of use cases presents a challenge. In this work, we present a method of tailoring wicking behavior to an arbitrary target function of propagation distance versus time, achieved through the use of AM to create nonuniform porous materials. Layers of parallel lines, each successive layer rotated 90° from the last, form a gridded structure with a spatially varying unit cell size for which analytical models for the capillary pressure and solid fraction and a semianalytical model for permeability were found. These models were validated with capillary rise experiments for spatially uniform porous materials over a range of solid fractions from 0.4 to 0.9. Leveraging these models and representing a nonuniform porous material as a series of Ohmic fluidic resistors, we created an inverse design algorithm that generates a wicking material with spatially varying parameters to achieve a specified target function for fluid propagation as a function of time. These materials can exhibit atypical wicking behavior, including fluid propagation displaying simple linear and piecewise linear relationships with time rather than the conventional Washburn relationship.