System and methods for forming a micropillar array for an evaporative heat exchanger include selecting a preliminary shape for a micropillar, determining a droplet shape that is generated by the preliminary shape, and generating at least one curve that defines the droplet shape. The system and methods also include performing an evaporative simulation based on the curve and selecting a final micropillar shape based on the evaporative simulation. The system and methods further include fabricating an array of micropillars including at least one micropillar having the final micropillar shape.
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