Triply periodic minimal surface heat exchanger: Innovations, mathematical modelling, and performance enhancement-a state-of-the-art review

This state-of-the-art review synthesizes the most recent advances in Triply Periodic Minimal Surface (TPMS) heat exchangers, a transformative technology designed to meet the growing demand for high-performance, compact, and reliable thermal management systems in next-generation applications, including aerospace, nuclear energy, and high-performance electronics. Systematically analyzing 50 key publications from 2020 to 2026, the review organises findings into four thematic areas: novel TPMS configurations and performance comparisons; advanced design with gradient structures; surface modification and texturing; and manufacturing, characterisation, and application-specific validation. Results demonstrate that TPMS-based heat exchangers substantially outperform conventional designs, such as printed circuit (PCHE) and plate heat exchangers, delivering 15–100% higher thermal performance, 16–120% greater Nusselt numbers, and 2–3 times higher heat transfer rates within approximately half the volume. Top-performing topologies include Gyroid and Schwarz-Diamond structures, with Gyroid units achieving up to 54% greater efficiency than traditional plate exchangers. Recent innovations in gradient and hybrid TPMS designs enhance convective heat transfer by 26–60% while reducing pressure drop by 9.7–18%. Additive manufacturing enables the fabrication of intricate geometries, yielding performance improvements such as a 358% increase in the j/f factor for copper Fischer-Koch S structures. Surface texturing techniques (including Voronoi-based algorithms and abrasive jet polishing) further enhance performance, reducing pressure drop by up to 40% and increasing heat transfer coefficients by up to 34.11%. Despite challenges related to the cost, long-term reliability, fouling, and standardization of additive manufacturing, TPMS heat exchangers are inherently transformative. Their biomimetic geometries, exceptional surface-area-to-volume ratios, and design flexibility enhance material and operational efficiency, rendering them lifecycle cost-effective. As such, they represent a pivotal technology for performance-sensitive applications where thermal efficiency and compactness are critical. Triply periodic minimal surface heat exchangers: a paradigm shift in compact thermal management.