Design and manufacturing optimization of innovative heat exchangers: a multi dimensional approach in industrial systems

In the current industrial landscape, the growing demand for customized, high performance products is driving manufacturing companies to reassess their design processes through the adoption of advanced technologies. In particular, optimizing both the performance and efficiency of thermal components, such as heat exchangers, has become a key challenge in the pursuit of efficient and sustainable solutions. This study aims to identify the optimal combination of manufacturing parameters for the production of heat exchangers. To achieve this, prototypes were designed and fabricated by combining different polymer resins with distinct geometries. The structural performance of each prototype was assessed through mechanical testing, and the production behaviour was taken into consideration. A Multi-Criteria Decision-Making (MCDM) approach was adopted to determine the optimal resingeometry configuration. Specifically, the Analytic Hierarchy Process (AHP) was used to assign relative weights to the evaluation criteria, while the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) was applied to rank the alternatives. This integrated methodology enabled a systematic assessment of design options, supporting the selection of the best trade-off between mechanical performance and production cost.