Optimizing DMLS support structures for powder removal

Hi everyone, we’re looking to use DMLS to create intricate internal channels in a complex heat exchanger for a miniaturized cooling system in a portable medical device. Our main challenge is optimizing the design for both thermal efficiency and manufacturability. We’re aiming for a compact unit, approximately 100mm x 50mm x 30mm, with internal channels as small as 0.5mm in diameter. The material we’re considering is AlSi10Mg for its excellent thermal conductivity and corrosion resistance.

My specific question is about support structures for these internal channels. Given the complexity of our design, I’m concerned about powder removal post-printing. Has anyone here successfully implemented self-supporting geometries for similar small, intricate channels in DMLS? If so, what were your key design considerations to ensure proper powder evacuation while maintaining the structural integrity of the part?