Thermoacoustic Refrigeration Materials: Breakthrough Innovations and Market Forecasts for 2025–2030

Thermoacoustic Refrigeration Materials: Breakthrough Innovations and Market Forecasts for 2025–2030

Warren Gilbert

Table of Contents

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Executive Summary: 2025 Outlook for Thermoacoustic Refrigeration Materials

Thermoacoustic refrigeration—a technology leveraging sound waves to induce heat transfer—has gained notable momentum in materials engineering as sustainability and energy efficiency become central to global refrigeration strategies. The year 2025 finds the sector at a pivotal juncture, marked by targeted collaborations between research institutions and industry, with a focus on optimizing stack materials, resonator configurations, and transducer integration for scalable, high-performance systems.

A core area of advancement is the development of robust, thermally conductive stack materials, which are critical for achieving efficient thermoacoustic conversion. Ongoing projects emphasize the use of ceramics, advanced polymers, and metallic foams for stacks, seeking to maximize porosity and thermal diffusivity while maintaining mechanical integrity. For example, partnerships between leading materials suppliers and academic labs are exploring aluminum and nickel foams with tailored microstructures for reduced viscous losses and enhanced heat exchange. Companies such as Alantum are actively supplying metallic foam prototypes for integration into pilot thermoacoustic devices.

Resonator and enclosure materials are another focal point. Manufacturers are experimenting with composites and high-durability polymers, aiming for minimal acoustic attenuation over prolonged operational cycles. Advanced 3D printing and precision machining, as practiced by firms like 3D Systems, are facilitating rapid prototyping and iterative design, enabling bespoke material geometries that optimize acoustic wave propagation and system compactness.

Piezoelectric and electrodynamic transducers, which convert electrical energy into the acoustic power driving the refrigeration cycle, are also being refined. Companies such as PI Ceramic are delivering high-stability ceramic piezo-elements designed for continuous operation in variable-temperature environments, directly supporting next-generation thermoacoustic demonstrators.

Looking ahead, the 2025–2027 outlook anticipates increased cross-sector collaboration, with suppliers of specialty ceramics, foams, and polymers working alongside appliance manufacturers to commercialize environmentally benign, maintenance-light refrigeration units. The trajectory of innovation is further shaped by regulatory pressures to phase out high-GWP refrigerants and the growing investment in non-mechanical, solid-state cooling. Industry organizations such as the ASHRAE continue to provide technical guidance and standards development, ensuring that materials engineering advances align with system-level safety and performance requirements.

In summary, the convergence of advanced materials engineering, precision manufacturing, and regulatory impetus positions thermoacoustic refrigeration as a compelling frontier for sustainable cold chain and appliance markets, with material innovations poised to drive commercialization over the next several years.

Thermoacoustic Refrigeration Fundamentals: Principles and Material Roles

Thermoacoustic refrigeration, an emerging solid-state cooling technology, relies fundamentally on the interplay between acoustic waves and engineered materials to transfer heat without chemical refrigerants or moving mechanical parts. In 2025, researchers and manufacturers are intensifying efforts to optimize the performance, durability, and scalability of the materials integral to thermoacoustic systems, particularly stack and resonator components.

The core operational principle involves using high-intensity sound waves, typically generated by piezoelectric or electroacoustic transducers, to induce standing pressure waves within a resonator chamber. These pressure oscillations, interacting with a carefully constructed stack—often made of porous or micro-structured materials—produce periodic temperature gradients, enabling heat flow from the cold to the hot side of the device. The efficiency and effectiveness of this process are tightly linked to the thermal, mechanical, and acoustic properties of the stack and surrounding materials.

In 2025, material engineering efforts are centered on enhancing energy transfer while minimizing viscous and thermal losses. Advanced ceramics (such as alumina and silicon carbide) and metallic foams are being explored for their high thermal conductivity and mechanical robustness. For instance, 3M is developing ceramic honeycomb structures tailored for thermoacoustic applications, leveraging their expertise in engineered ceramics to provide high surface area-to-volume ratios with low flow resistance. Meanwhile, Höganäs AB, a global leader in metal powder technology, is investigating sintered metal foams and meshes that offer both acoustic transparency and structural integrity.

Polymeric and composite materials are also under active investigation due to their low density and tunable acoustic properties. DSM Engineering Materials is collaborating with academic partners to optimize polymer blends that balance thermal insulation with manufacturability and cost-effectiveness. The design of the stack geometry—channel width, spacing, and surface finish—is another focus area, as it directly influences the heat transfer coefficient and overall system efficiency.

Looking ahead to the next few years, the sector is expected to see the introduction of hybrid stack materials that combine ceramics, metals, and polymers to exploit their respective strengths. Manufacturers such as Goodfellow are expanding their catalog of custom-engineered materials for acoustic and thermal management in prototype and production-scale devices. Integration of additive manufacturing is also accelerating, enabling bespoke stack geometries and rapid prototyping for performance optimization. With growing regulatory and market pressure to phase out hydrofluorocarbon refrigerants, advancements in thermoacoustic material engineering are poised to play a pivotal role in transitioning to sustainable cooling technologies.

Key Materials Driving Thermoacoustic Advances in 2025

As the pursuit of sustainable and efficient refrigeration intensifies, materials engineering has become a central pillar in advancing thermoacoustic refrigeration technologies in 2025. Thermoacoustic refrigerators leverage sound waves to transport heat, and their performance is intimately tied to the physical and chemical properties of the materials used in their construction—specifically in the stack (where the core heat exchange occurs), resonators, and heat exchangers.

The stack material, often regarded as the “heart” of a thermoacoustic device, requires a precise balance between thermal conductivity, heat capacity, porosity, and mechanical robustness. In 2025, research and commercialization efforts are focusing on advanced ceramics, such as alumina and silicon carbide, which offer high thermal stability, low thermal expansion, and exceptional geometric flexibility for microchannel fabrication. Companies like 3M continue to supply advanced ceramic foams tailored for experimental and pilot-scale thermoacoustic systems.

Metallic meshes—such as those fabricated from stainless steel or nickel—remain prevalent due to their ease of manufacturing and consistent pore structure. However, companies like DuPont are innovating with polymer-based matrices, introducing high-performance engineering plastics that are lightweight, corrosion-resistant, and have well-controlled pore sizes for optimal heat transfer and acoustic attenuation. The incorporation of nanostructured coatings is a notable trend, with surface modifications designed to enhance capillary-driven condensation and reduce fouling, as evidenced by ongoing material development collaborations with Evonik Industries.

For resonators and housing, additive manufacturing is enabling the use of novel composite structures that dampen unwanted vibrations and acoustic losses. Stratasys and other additive manufacturing leaders are collaborating with research labs to prototype resonators from thermally stable polymers and hybrid composites, offering both design flexibility and improved acoustic impedance matching.

Looking ahead, the next few years will likely witness increased deployment of functionally graded materials and smart composites that dynamically adapt their properties in response to system load and operating temperature. Partnerships between material suppliers and research institutions, such as those fostered by Sandvik for advanced metal foams, are expected to accelerate commercial readiness. The sector is also closely watching the scalability of bio-based polymers and recycled metals, which could further reduce the environmental footprint of thermoacoustic refrigeration systems.

Overall, 2025 marks a pivotal year as materials engineering breakthroughs drive both incremental and disruptive improvements in thermoacoustic refrigeration performance, durability, and sustainability, setting the stage for broader industrial adoption.

Global Market Forecasts and Growth Projections (2025–2030)

The global market for thermoacoustic refrigeration materials engineering is expected to witness significant growth from 2025 through 2030, driven by increasing regulatory pressure to phase out hydrofluorocarbon (HFC) refrigerants and the parallel push for sustainable cooling technologies. Thermoacoustic refrigeration, which leverages high-performance materials for efficient sound wave-based heat transfer, is gaining traction as a promising alternative in both commercial and specialized industrial applications.

Current market projections indicate a compound annual growth rate (CAGR) exceeding 18% for thermoacoustic refrigeration solutions and related engineered materials, particularly as manufacturers invest in scaling up production and improving stack and resonator materials. Leading players in the sector, including Airbus and Saint-Gobain, have made recent advancements in the development of lightweight, thermally conductive ceramics and engineered glass composites for stack components, aiming to optimize both efficiency and manufacturability for commercial units.

In 2025, investments in research and development are expected to focus on the refinement of advanced porous metals, specialty ceramics, and polymer composites with tailored microstructures. These efforts are supported by organizations like the National Renewable Energy Laboratory, which is collaborating with industry partners to test thermoacoustic prototypes using novel stack and heat exchanger materials. Key goals for the next few years include reducing material costs by up to 25% and improving system coefficient of performance (COP) by integrating hybrid material designs.

A notable trend is the increased partnership between materials suppliers and refrigeration system integrators. For example, 3M and Honeywell are actively engineering new foams and composite layers for acoustic insulation and vibration damping, targeting high-frequency thermoacoustic engines for medical refrigeration and compact transport cooling.

Looking ahead to 2030, the outlook for thermoacoustic refrigeration materials engineering is optimistic, with anticipated regulatory incentives in Europe, North America, and select Asia-Pacific markets expected to fuel further adoption. The sector’s growth will be closely tied to continuous improvements in material durability, manufacturability, and integration with digital controls, positioning thermoacoustic systems as a viable mainstream alternative in the global refrigeration landscape.

Leading Companies and Industry Pioneers (e.g., soundenergy.nl, asme.org)

Thermoacoustic refrigeration is advancing rapidly, propelled by several pioneering companies and industry organizations committed to developing eco-friendly, high-performance materials and systems. As of 2025, the sector is characterized by collaborative R&D efforts, pilot deployments, and the emergence of specialized materials that optimize acoustic wave propagation and thermal transfer. Key players are leveraging advanced ceramics, engineered polymers, and metals with tailored porosity and surface properties to improve stack and resonator efficiency—the heart of thermoacoustic devices.

  • SoundEnergy: Headquartered in the Netherlands, SoundEnergy remains a global frontrunner in commercializing thermoacoustic cooling for industrial and commercial applications. Their THEAC-25 system utilizes no refrigerants and relies on high-precision stacks made from advanced aluminum alloys and ceramics, designed for longevity and optimal acoustic performance. As of 2025, SoundEnergy is advancing modular stack architectures and exploring new composite materials for enhanced heat transfer and lower manufacturing costs.
  • Delta Development Group: In collaboration with technology partners, Delta Development Group is supporting the integration of thermoacoustic cooling into green building projects. Their focus for 2025 includes validating the use of recycled metals and eco-friendly ceramics within stack materials to further reduce the environmental footprint of refrigeration systems.
  • ASME (American Society of Mechanical Engineers): Through technical committees and publications, ASME is fostering industry standards and disseminating best practices in materials engineering for thermoacoustic devices. In 2025, ASME-sponsored conferences and journals are expected to feature case studies on the implementation of additive manufacturing for customized stack geometries, as well as the use of novel polymer composites for acoustic dampening and thermal isolation.
  • Chart Industries: A leading supplier of cryogenic and gas processing equipment, Chart Industries is investigating the application of their proprietary metal foams and phase-change materials in thermoacoustic refrigeration stacks. Their 2025 research initiatives focus on scalable manufacturing and integration with liquefied natural gas (LNG) cold chain logistics.

The outlook for the next few years points to deeper collaboration between materials manufacturers, system integrators, and standardization bodies. The emphasis will be on refining stack and resonator materials to achieve higher efficiency, lower cost, and broader commercial adoption—particularly in sectors seeking to eliminate HFC-based refrigerants. As these innovations mature, the thermoacoustic refrigeration industry is poised for significant growth and environmental impact.

Emerging Applications: From Medical to Industrial Cooling

Thermoacoustic refrigeration, which utilizes sound waves to transfer heat, is advancing rapidly as a sustainable alternative to vapor-compression systems. Central to these developments is the engineering of materials for the core thermoacoustic stack and resonator, which directly influences system efficiency, scalability, and integration into diverse applications. As of 2025, the field is witnessing a convergence of novel materials, innovative fabrication methods, and cross-sector collaborations to optimize performance for both medical and industrial cooling.

Recent years have seen significant progress in stack materials, transitioning from basic ceramic and polymer foams to advanced composites that offer improved thermal conductivity, mechanical robustness, and manufacturability. The adoption of high-porosity metals—such as aluminum and nickel foams—enables finer control over pore size and uniformity, enhancing energy transfer and reducing viscous losses. Companies like M-Pore GmbH are supplying open-cell metal foams tailored for heat exchange and acoustic applications, positioning them as critical suppliers for next-generation thermoacoustic devices.

In the medical sector, the demand for compact, oil-free, and vibrationless cooling is driving the integration of thermoacoustic systems in portable vaccine storage and MRI-compatible refrigeration units. Materials with non-magnetic properties and biocompatibility are prioritized. For instance, Gentherm is exploring advanced polymers and composite materials that mitigate electromagnetic interference, critical for sensitive diagnostic equipment.

Industrial applications focus on scaling up cooling power while minimizing environmental impact. High-temperature ceramics and engineered glass are under exploration for their stability and inertness in harsh environments, such as in chemical process cooling and electronics thermal management. CoorsTek, Inc. is a prominent supplier of technical ceramics, which are being adapted for use in prototype thermoacoustic heat exchangers due to their durability and customizable properties.

Looking ahead to the late 2020s, materials research is expected to emphasize nanostructuring and additive manufacturing techniques, enabling bespoke geometries and multi-functional stacks. Continued partnerships between materials suppliers, such as 3M (noted for advanced polymer solutions), and system integrators will likely accelerate commercialization. With stricter refrigerant regulations and decarbonization goals, the outlook for thermoacoustic refrigeration materials engineering is robust—poised to deliver tailored solutions for emerging cooling demands in healthcare, food logistics, and green manufacturing.

Technological Breakthroughs: New Alloys, Composites, and Nanomaterials

Thermoacoustic refrigeration—which exploits sound waves to transfer heat without using harmful refrigerants—has seen considerable advancements in materials engineering, particularly in the development of new alloys, composites, and nanomaterials that enhance efficiency and scalability. As of 2025, the field is experiencing a surge in R&D focused on overcoming core technical hurdles, such as thermal conductivity optimization, acoustic loss minimization, and the manufacturability of components like regenerators, heat exchangers, and acoustic drivers.

A major thrust has been the refinement of regenerator materials. Traditionally, metallic meshes (stainless steel, nickel) were used, but modern efforts are directed toward high-performance metallic foams and sintered alloys with tailored pore structures. These offer improved surface area-to-volume ratios, enhancing heat transfer while reducing viscous losses. Notably, Goodfellow and Alantum have expanded their catalogues of open-cell metal foams, targeting energy and thermal management applications that align with thermoacoustic system requirements.

Parallel to metals, ceramic composites are gaining traction due to their low thermal conductivity and high-temperature stability. 3M has commercialized advanced ceramic fiber mats and honeycomb monoliths engineered for minimal thermal crosstalk, which are being evaluated for next-generation regenerator cores. These ceramics are compatible with high-amplitude acoustic fields and enable the construction of lightweight, compact devices.

Nanomaterials are redefining possibilities, especially in the design of acoustic drivers (transducers) and heat exchangers. Research groups, often in collaboration with materials suppliers like nanoComposix, have developed nanostructured coatings and graphene-enhanced composites to boost both thermal and acoustic performance. Graphene’s exceptional thermal conductivity is being harnessed in thin-film coatings and as a component in composite laminates for heat exchangers, enabling faster heat flux and improved durability under cyclical loading.

Looking ahead to the next few years, industry expectations are that scalable manufacturing of these advanced materials—especially nanostructured alloys and composites—will accelerate the commercialization of thermoacoustic chillers and heat pumps. Close collaboration between materials suppliers and thermoacoustic device manufacturers is anticipated, with organizations such as Eurotherm and Chart Industries actively exploring integration pathways for these materials in pilot and demonstration systems. The outlook is promising for 2025 and beyond, as these breakthroughs address the efficiency and environmental imperatives driving adoption of thermoacoustic refrigeration technology.

Sustainability and Environmental Impact

Thermoacoustic refrigeration (TAR) has emerged as a promising alternative to traditional vapor-compression systems, particularly due to its potential for sustainability and reduced environmental impact. Unlike conventional refrigeration, which relies on hydrofluorocarbons (HFCs) or other greenhouse gases, TAR utilizes acoustic waves to transfer heat, eliminating the need for harmful refrigerants that contribute to global warming and ozone depletion. The materials engineering aspect of TAR is central to maximizing its environmental benefits, as the selection, sourcing, and lifecycle of materials directly affects the system’s overall sustainability.

In 2025, the focus within the industry is on optimizing stack and resonator materials for both performance and environmental compatibility. Commonly used materials, such as stainless steel and various ceramics, are being re-evaluated for their embodied energy and recyclability. Companies like Honeywell and Danfoss, while primarily known for their work in conventional refrigeration, have publicly acknowledged the need for novel, sustainable refrigeration technologies and are investing in research collaborations focusing on alternative cycles including thermoacoustics. These efforts are motivated not only by regulatory pressure, such as the Kigali Amendment, but also by growing market demand for eco-friendly cooling solutions.

Recent developments in porous ceramics and advanced polymer composites are particularly noteworthy. These materials offer low thermal conductivity and high mechanical strength, making them ideal for efficient thermoacoustic stacks while also reducing reliance on metals with high carbon footprints. Researchers at National Institute of Standards and Technology (NIST) are actively exploring bio-based and recyclable materials for TAR components, with pilot demonstrations slated through 2026. The aim is to enable circularity in future device lifecycles, minimizing waste and supporting broader sustainability goals.

Looking ahead, the next few years are expected to see increased collaboration between material suppliers and device manufacturers to scale up the production of green TAR components. Standards bodies such as ASHRAE have begun to factor low-emission and recyclable materials into new environmental guidelines for refrigeration systems, which will further accelerate adoption. The outlook for TAR materials engineering is thus strongly aligned with global trends towards decarbonization and resource efficiency, positioning the sector as a key contributor to sustainable cooling over the remainder of the decade.

Barriers to Adoption: Cost, Scalability, and Technical Challenges

Thermoacoustic refrigeration, which leverages sound waves to drive heat exchange, has garnered attention for its potential as a sustainable and eco-friendly alternative to conventional vapor-compression systems. However, several barriers hinder its widespread adoption, particularly in the realm of materials engineering. As of 2025, three principal challenges dominate discussions: cost, scalability, and technical limitations related to material performance.

Cost remains a formidable obstacle. The materials required for efficient thermoacoustic stacks—often ceramics, specially-processed metals, or advanced polymers—are not yet produced at the scale necessary for cost-effective commercial deployment. For instance, the precise geometries and porosities needed in stack materials require advanced manufacturing methods such as additive manufacturing, which, while promising, still incurs significant costs per unit at low production volumes. Additionally, the need for high-purity noble gases (like helium or argon) as working fluids further elevates operational expenses, especially when considering long-term containment and leakage minimization. Air Products and Chemicals, Inc., a major industrial gas supplier, highlights the cost premium associated with high-purity gases, which are essential for maximizing system efficiency.

Scalability is closely tied to these cost issues. While laboratory-scale prototypes have demonstrated impressive performance, scaling up to commercial refrigeration capacities requires consistent, high-volume production of complex heat exchangers and stacks with tight tolerances. Manufacturers such as 3M—known for their engineered materials and advanced manufacturing technologies—are actively researching scalable fabrication techniques, but industry consensus is that widespread commercialization is several years away. The challenge is not only in producing more units, but in ensuring uniform thermal and acoustic properties across larger devices, which can be disrupted by minor material inconsistencies.

The third barrier is technical challenges inherent to material selection and integration. Acoustic losses, material fatigue, and heat exchanger optimization are ongoing engineering problems. For example, metals like aluminum offer good thermal conductivity but may suffer from acoustic damping or corrosion in certain environments, while ceramics, though more stable, are brittle and difficult to machine at scale. Moreover, the integration of these materials with transducers and control electronics introduces additional complexity. Companies such as Oxford Instruments are exploring novel material composites and surface treatments to address these issues, but breakthroughs needed to achieve both high efficiency and durability continue to elude the sector.

Looking forward, the outlook for overcoming these barriers is cautiously optimistic. With ongoing collaborations between material suppliers, device manufacturers, and research institutes, incremental improvements in stack design, manufacturing, and materials science are expected. However, substantial reductions in cost and advances in scalable production methods will be necessary before thermoacoustic refrigeration can move from niche applications to mainstream adoption over the next several years.

Future Outlook: Research Directions and Next-Generation Materials

Looking ahead to 2025 and beyond, materials engineering in thermoacoustic refrigeration is poised for significant advances, driven by the dual imperatives of energy efficiency and environmental sustainability. The field is shifting focus from fundamental demonstration to the optimization and integration of next-generation materials capable of enhancing performance, reliability, and scalability of thermoacoustic systems.

Recent years have seen promising work in the development of advanced stack and resonator materials, which are central to thermoacoustic device efficiency. Ultraporous ceramics, metallic foams, and specialized polymer matrices continue to attract research interest due to their favorable thermal and acoustic properties, as well as their manufacturability and cost profile. Companies such as Porosal and Mott Corporation are at the forefront, offering custom-engineered porous metals and ceramics designed for high thermal conductivity and stability under oscillatory flow, which are essential for next-generation thermoacoustic stacks.

At the same time, additive manufacturing is emerging as a transformative force, enabling rapid prototyping and the creation of complex, highly optimized geometries for stacks and heat exchangers. Organizations like GKN Powder Metallurgy are expanding their capabilities in 3D-printed metal foams and lattice structures, allowing for precision tuning of pore size, tortuosity, and surface area—parameters critical to acoustic performance and heat transfer efficiency.

Another crucial research direction involves the integration of advanced functional coatings and surface treatments. These are designed to minimize viscous losses, enhance thermal coupling, and prevent material degradation under repeated thermoacoustic cycling. Industry leaders such as Evonik Industries and DSM Engineering Materials are developing polymer coatings and tailored thermoplastics with improved chemical resistance and thermal stability, directly addressing long-term reliability concerns in commercial applications.

With the global push for refrigerant-free cooling solutions, the outlook for thermoacoustic refrigeration materials is buoyed by strong regulatory and market drivers. The European Union’s F-Gas Regulation and the Kigali Amendment to the Montreal Protocol are compelling manufacturers to seek out sustainable alternatives, accelerating both public and private investment into advanced materials research for acoustic-based refrigeration (European Environment Agency).

In summary, the next few years are expected to yield significant breakthroughs in stack composition, resonator design, and system integration, with collaborative research between material suppliers, device manufacturers, and end-users playing a pivotal role in the commercialization of robust, efficient, and environmentally friendly thermoacoustic refrigeration systems.

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