A Bio-Inspired Approach to Flexible Tubular Heat Exchanger Design for Wearable Medical Technology

Flexible heat exchangers with intricate three-dimensional (3D) geometries exhibit superior mechanical and thermal performance compared with traditional two-dimensional (2D) designs. Their ability to offer greater design freedom and unique functionalities makes them particularly attractive for wearable medical devices. This study investigates flexible heat exchanger technologies in three main directions: (i) miniaturisation, (ii) integration of physical and mathematical models, and (iii) enhanced adaptability through heterogeneous design integration. Through a combination of literature review, mathematical modelling, and experimental analysis, the thermal efficiency of several configurations is compared, including basic thermoplastic polyurethane (TPU) tubes and 3D bio-inspired TPU tubes with aluminium-finned structures. The findings establish a foundation for the development of next-generation flexible wearable medical cooling devices with improved thermal management capabilities and practical applicability in industrial design. Furthermore, the outcomes of this research will directly support the development of improved wearable cooling devices within a UK-based medical device SME, Paxman Scalp Coolers, facilitating the translation of advanced heat exchanger designs into clinically relevant and commercially viable solutions.