Topology optimization of porous electrodes for electrochemical flow reactors using the finite element method and triply periodic minimal surfaces

Porous electrodes are essential components in electrochemical technologies for energy conversion and storage, where they facilitate mass and fluid transport, provide active reaction sites, and significantly influence system performance and cost. Traditionally, electrode design has relied heavily on empirical experimentation, a process that is both time- and resource-intensive. In contrast, predictive computational algorithms, such as topology optimization, offer a promising pathway to accelerate the design process by identifying optimal electrode structures meeting the specified performance targets. In this work, we present a high-performance topology optimization framework integrated with a multi-physics computational model that captures key transport phenomena in electrochemical flow cells. The framework iteratively identifies electrode structures optimized to maximize electrochemical power output while minimizing pumping losses. Our simulations demonstrate that the optimized electrode designs can reduce overpotential losses by up to 29% and hydraulic power dissipation by up to 98%. We then translate the optimized structures into cellular architectures using triply periodic minimal surfaces (TPMS) and successfully fabricated them using stereolithography 3D printing, demonstrating the practical manufacturability of the proposed geometries. We envision that this computational design approach can guide next-generation electrode architectures, inspire new manufacturing strategies, and be extended to other electrochemical systems beyond flow cells. • The developed topology optimization model can be used to predict optimal porous electrode designs. • Computed designs showed enhanced electrical and hydraulic performance. • Designs were translated to TPMS architectures and manufactured with stereolithography. • The proposed framework can be adapted to various electrochemical systems.