A heat recovery wheel for a heat exchanger includes a wheel rim defining an outer perimeter of the heat recovery wheel, and a plurality of wheel passages located between the wheel rim and the wheel axis. The plurality of wheel passages are arranged in a plurality of radial layers relative to a wheel central axis. Each layer is defined by a first shaped material having a first cross-sectional shape and a second shaped material assembled to the first shaped material, the second shaped material having a second cross-sectional shape. Radially adjacent layers of the plurality of layers are secured directly to one another, and the plurality of wheel passages are configured for flow of a first airflow and a second airflow therethrough for thermal energy exchange between the first airflow and the second airflow.