Additive manufacturing (AM) enables the creation of complex internal geometries, including cooling channels. Yet, the impact of AM-induced surface roughness on their fluid dynamics remains underexplored. The goal of this study is to provide insight into the effects of surface roughness on the fluid dynamics of AM channels. A parametric surface roughness model and computational fluid dynamics (CFD) simulations were employed to examine three representative AM channel cross-sections: diamond, droplet, and circular. The findings indicate that diamond profiles result in higher pressure losses and turbulence intensity compared to the other cross-sections. In contrast, droplet profiles exhibit lower pressure losses and turbulence intensity compared to diamond profiles, while circular channels remain optimal in non-overhang areas.
