Additive manufacturing of TPMS structures for lightweight and multifunctional applications

Weight reduction of components and parts is critical in aerospace, automotive and biomedical engineering, driving the demands for materials and structures with high strength-to-weight ratios to improve efficiency. Triply periodic minimal surface structures have gained significant attention for lightweight multifunctional applications due to their unique combination of high strength-to-weight ratio, excellent energy absorption, large surface area and tunable mechanical properties. These characteristics enable triply periodic minimal surface structures to provide not only structural support and weight reduction but also enhanced thermal management, fluid transport and biological performance, making them attractive for next-generation engineering applications. Several triply periodic minimal surface architectures have emerged as promising models for their exceptional mechanical properties, energy absorption and ability to mimic natural structures. However, the complexity of these geometries has limited their realization through conventional manufacturing processes. Additive manufacturing has fostered the ability to fabricate these intricate lattices and triply periodic minimal surface structures with precise topology and material distribution. The design freedom offered by additive manufacturing makes it possible to produce complex triply periodic minimal surface geometries that are otherwise difficult or impossible to manufacture using traditional methods. This review highlights an overview of the state of the art in lightweight lattice and triply periodic minimal surface research, focusing on three key aspects: materials, design methodologies and additive manufacturing strategies. These materials, ranging from metals to polymers and ceramics, are discussed in relation to their performance in lattice applications. Design approaches, including topology optimization, computational modelling and biomimetic structures, are highlighted besides additive manufacturing processes such as laser powder bed fusion, electron beam melting, material extrusion and binder jetting. Key challenges, such as defects and anisotropies, are examined, with an emphasis on their impact on structural integrity. Emerging directions, such as multimaterial additive manufacturing, sustainability and artificial intelligence-driven designs, are outlined, providing the roadmap for future direction and developments. This review aims to serve as a reference for researchers and engineers seeking to harness triply periodic minimal surface structures for next-generation lightweighting solutions.