Thermal protection systems play a pivotal role in astronautical engineering fields. However, traditional rectangular fin (RF) structures exhibit low thermo-fluid properties. Inspired by the minimal surfaces in nature, this study develops three types of triply periodic minimal surface (TPMS) lattices, namely, sheet primitive (SP), network I-WP (NW), and sheet I-WP (SW) by using mathematical formulae. The TPMS lattices are fabricated by laser powder bed fusion using AlSi10Mg powder. A convective heat transfer simulation model of TPMS lattices is established and validated through experiments. The fluid flow characteristics, heat transfer characteristics, and overall heat transfer performance of the TPMS lattices are comprehensively investigated based on the simulation model. Results show that the relationship between pressure loss and flow velocity of the TPMS lattices satisfies the Darcy–Forchheimer law. Compared to traditional RF structures, the TPMS lattices exhibit a more uniform temperature distribution at the same flow rate, and the highest convective heat transfer coefficient is increased by approximately 96.62%. This is due to the complex internal structures of the TPMS lattices, which enhance the disturbance of the fluid flow and further improve the heat transfer coefficient. The overall thermal transfer index ($\alpha$) of the TPMS lattices is higher than that of traditional RF structures with an order of ${\alpha }_{SP}>{\alpha }_{SW}>{\alpha }_{NW}>{\alpha }_{RF}$, which confirms the potential applications of TPMS lattices in thermal protection systems.

Promoting the development of aerospace vehicles toward structural–functional integration and intelligent sensing is a key strategy for achieving lightweight, high-reliability, and autonomous operation and maintenance of next-generation aircraft. However, traditional external sensors face significant limitations because of their bulky size, installation challenges, and incompatibility with aerodynamic surfaces. These issues are particularly pronounced on complex, high-curvature substrates, where achieving conformal bonding is difficult, thus restricting their application in critical components. In this study, aerosol jet printing (AJP) was employed to directly fabricate silver nanoparticle-based temperature sensors with real-time monitoring capabilities on the surface of high-curvature stainless steel sleeves, which serve as typical engineering components. This approach enables the in situ manufacturing of high-precision conformal sensors. Through optimized structural design and thermal treatment, the sensors exhibit reliable temperature sensitivity. Microscopic characterization reveals that the printed sensors possess uniform linewidths and well-defined outlines. After gradient sintering at 250 °C, a dense and continuous conductive path is formed, ensuring strong adhesion to the substrate. Temperature-monitoring results indicate that the sensor exhibits a nearly linear resistance response (R² > 0.999) across a broad detection range of 20–200 °C. It also demonstrates high sensitivity, characterized by a temperature coefficient of resistance (TCR) of 2.15 × 10^−3/°C at 20 °C. In repeated thermal cycling tests, the sensor demonstrates excellent repeatability and stability over 100 cycles, with resistance fluctuations kept within 0.5% and negligible hysteresis observed. These findings confirm the feasibility of using AJP technology to fabricate high-performance conformal sensors on complex surfaces, offering a promising strategy for the development of intelligent structural components in next-generation aerospace engineering.