This contribution presents a new optimization procedure for the design of the appendix gap in Stirling engines. This is of special interest, because the thermal losses associated with the appendix gap, an annular gap around the displacer in the cylinder system, may amount to as much as 10% of the heat input to a Stirling engine. Furthermore, recent experimental investigations and an extensive literature review revealed that the accuracies of the existing models for these losses and the derived design rules for the appendix gap are insufficient. The optimization procedure presented here is based on a recently developed and published, more detailed analytical model. To generally analyze any optimization potential, this model is first subject to numerical optimization. The choice of the correct gap width implies a major optimization potential, but there are additional options (e.g., choosing a conical design with an expansion towards the open end). Thus, the loss can be reduced by more than 10%. Furthermore, the gap loss can be reduced by a modification of the seal design, reducing the volumetric displacement and the almost isothermal buffer volume at the bottom end of the gap. If the gap width is minimized in the bottom section of the gap, a larger optimum width is obtained for the remaining length of the gap, and no conicity is needed. Finally, an analytical, easily applicable, closed-form approximate solution for the optimum gap width and the corresponding overall gap loss has been derived and validated. Nomenclature A = area, m 2 a = thermal diffusivity, m 2 ∕s b = complex constant c D = specific heat capacity of the displacer wall, J∕kg · K c h = conicity c p = specific isobaric heat capacity, J∕kg · K d = diameter, m f = factor for the evaluation of the optimum Péclet number H = enthalpy, J h = appendix gap width, m J = imaginary part i = imaginary unit (i −1 p ) J = function (velocity ratio) k = complex constant l = length, m m = mass, kg n = rotational speed, s −1 Pe ω = kinetic Péclet number (Pe ω 4h 2 ω∕a) Pr = Prandtl number (Pr ν∕a) p = pressure, Pa Q = heat, J R = specific gas constant, J∕kg · K R = real part Re ω = Valensi number (Re ω 4h 2 ω∕ν) r h = bottom gap width ratio r p = dimensionless pressure amplitude r x = dimensionless stroke amplitude T = Temperature, K u = flow velocity in x-direction, m∕s V C = swept volume of cylinder, m 3 x = axial coordinate, m x = displacer stroke amplitude, m Y = temperature gradient, K∕m Y 0 = overall temperature gradient, K∕m y = coordinate transverse to the gap, m Γ = velocity ratio (Γ û m ∕xω) δ = relative deviation Θ = dimensionless temperature θ p = phase angle of pressure relative to displacer velocity θ u = phase angle of mean flow velocity relative to displacer velocity Λ = complex factor (Poiseuille flow) λ = thermal conductivity, W∕m · K ν = kinematic viscosity, m 2 ∕s Ξ = complex constant ρ = density, kg∕m 3 Σ = overall loss, W φ = crank angle ω = angular velocity of crank shaft, s −1 ω 2πn Subscripts a = appendix gap ad = adiabatic bot = bottom end of ...