Rapid processing and assembly of semiconductor thermoelectric materials for energy conversion devices

Thermoelectric devices can convert heat to electricity. Recent advancements in the development of semiconductor thermoelectric materials have led to a significant increase in the thermoelectric figure of merit ZT. However, challenges in materials processing and assembly hinder the potential of thermoelectric power generation. An assessment of alternative advanced manufacturing methods for thermoelectric devices reveals the advantages of selective laser melting. While laser melting is a well-established additive manufacturing technique for metals, ceramics, and polymers, this study will provide the first investigations of semiconductor materials melt-processing using a laser. Preliminary experimental results demonstrate the effect of laser processing parameters on the microstructure and densification of the melt line. •Progress in thermoelectric power generation is hindered by material processing and assembly challenges.•Additive manufacturing methods can provide materials processing and assembly solutions for thermoelectric devices.•Selective laser melting of semiconductor thermoelectrics is proposed.•Single melt lines are formed on bismuth telluride materials using a selective laser melting technique.