Advanced Support Structures for Enhanced Catalytic Activity

3D-Printing of Hierarchical Porous Copper-Based Metal-Organic-Framework Structures for Efficient Fixed-Bed Catalysts

Metallic structures with hierarchical open pores that span several orders of magnitude are ideal candidates for various catalyst applications. However, porous metal materials prepared using alloy/dealloy methods still struggle to achieve continuous pore distribution across a broad size range. Herein, we report a printable copper (Cu)/iron (Fe) composite ink that produces a hierarchical porous Cu material with pores spanning over 4 orders of magnitude. The manufacturing process involves four steps: 3D-printing, annealing, dealloying, and reannealing. Because of the unique annealing process, the resulting hierarchical pore surface becomes coated with a layer of Cu-Fe alloy. This feature imparts remarkable catalytic ability and versatile functionality within fixed bed reactors for 4-nitrophenol (4-NP) reduction and Friedländer cyclization. Specifically, for 4-NP reduction, the porous Cu catalyst demonstrates an excellent reaction rate constant (kapp = 86.5 × 10-3 s-1) and a wide adaptability of the substrate (up to 1.26 mM), whilst for Friedländer cyclization, a conversion over 95% within a retention time of only 20 min can be achieved by metal-organic-framework-decorated porous Cu catalyst. The utilization of dual metallic particles as printable inks offers valuable insights for fabricating hierarchical porous metallic structures for applications, such as advanced fixed-bed catalysts.

Embedded 3D Printing of Architected Ceramics via Microwave-Activated Polymerization

Light- and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of one or more oxide materials. This integrated manufacturing method opens new avenues for the design and fabrication of complex ceramic architectures with programmed composition, density, and form for myriad applications.

The Role of 3D Printing in the Development of a Catalytic System for the Heterogeneous Fenton Process

Recycling of catalysts is often performed. Additive manufacturing (AM) received increasing attention in recent years in various fields such as engineering and medicine, among others. More recently, the fabrication of three-dimensional objects used as scaffolds in heterogeneous catalysis has shown innumerable advantages, such as easier handling and waste reduction, both leading to a reduction in times and costs. In this work, the fabrication and use of 3D-printed recyclable polylactic acid (PLA) scaffolds coated with an iron oxide active catalyst for Fenton reactions applied to aromatic model molecules, is presented. These molecules are representative of a wider class of intractable organic compounds, often present in industrial wastewater. The 3D-printed PLA-coated scaffolds were also tested using an industrial wastewater, determining the chemical oxygen demand (COD). The catalyst is characterized using electron microscopy coupled to elemental analysis (SEM/EDX) and thermogravimetry, demonstrating that coating leach is very limited, and it can be easily recovered and reused many times.

Novel monolithic catalysts for VOCs removal: A review on preparation, carrier and energy supply

Volatile organic compounds (VOCs) are considered the culprit of secondary air pollution such as ozone, secondary organic aerosols, and photochemical smog. Among various technologies, catalytic oxidation is considered a promising method for the post-treatment of VOCs. Researchers are sparing no effort to develop novel catalysts to meet the requirements of the catalytic process. Compared with the powdered or granular catalysts, the monolithic catalysts have the advantages of low pressure drop, high utilization of active phases, and excellent mechanical properties. This review summarized the new design of monolithic catalysts (including new preparation methods, new supports, and new energy supply methods) for the post-treatment of VOCs. It addressed the advantages of the new designs in detail, and the scope of applicability for each new monolithic catalyst was also highlighted. Finally, the highly required future development trends of monolithic catalysts for VOCs catalytic oxidation are recommended. We expect this work can inspire and guide researchers from both academic and industrial communities, and help pave the way for breakthroughs in fundamental research and industrial applications in this field.

Catalytic Materials by 3D Printing: A Mini Review

Catalytic processes are the dominant driving force in the chemical industry, proper design and fabrication of three-dimensional (3D) catalysts monoliths helps to keep the active species from scattering in the reaction flow, improve high mass loading, expose abundant active catalytic sites and even realize turbulent gas flow, greatly improving the catalytic performance. Three-dimensional printing technology, also known as additive manufacturing, provides free design and accurate fabrication of complex 3D structures in an efficient and economic way. This disruptive technology brings light to optimizing and promoting the development of existing catalysts. In this mini review, we firstly introduce various printing techniques which are applicable for fabricating catalysts. Then, the recent developments in 3D printing catalysts are scrutinized. Finally, challenges and possible research directions in this field are proposed, with the expectation of providing guidance for the promotion of 3D printed catalysts.

Customizing continuous chemistry and catalytic conversion for carbon–carbon cross-coupling with 3dP

Support structures of various materials are used to enhance the performance of catalytic process chemistry. Typically, fixed bed supports contain regular channels enabling high throughput because of the low pressure drop that accompanies high flow rates. However, many fixed bed supports have a low surface-area-to-volume ratio resulting in poor contact between the substrates and catalyst. Three dimensional polymer printing (3dP) can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed, including total bed surface area, as well as accommodating system integration features that are compatible with continuous flow chemistry. Additionally, 3dP allows for optimization of the catalytic process based on extrinsic constraints (e.g. operating pressure) and digital design features. These design parameters together with the physicochemical characterization and optimization of catalyst loading can be tuned to prepare customizable reactors based on objectives for substrate conversion and desired throughput. Using a Suzuki (carbon–carbon) cross-coupling reaction catalyzed by palladium, we demonstrate our integrated approach. We discuss key elements of our strategy including the rational design of hydrodynamics, immobilization of the heterogeneous catalyst, and substrate conversion. This hybrid digital-physical approach enables a range of pharmaceutical process chemistries spanning discovery to manufacturing scale.

First-principles design of hetero CoM (M = 3d, 4d, 5d block metals) double-atom catalysts for oxygen evolution reaction under alkaline conditions

As an extension of single-atom catalysts, the development of double-atom catalysts with high electrocatalytic activity for the oxygen evolution reaction (OER) is vital to facilitate hydrogen production and industrial applications. The CoM (M = 3d, 4d, 5d block metals) homo and double-atom catalysts supported on nitrogen-doped graphene (CoM/N₄G) were prepared for electrochemical water oxidation under alkaline conditions, and the electrocatalytic activity was studied through density functional theory (DFT) calculations. The hetero CoCu/N₄G double-atom catalyst indicated the highest OER activity with an onset potential of 0.83 V, while the homo Co₂/N₄G catalyst showed a higher onset potential of 1.69 V. The decoupled strain, dopant, and configurational effects based on the notable differences between the homo Co₂/N₄G and CoCu/N₄G explained the enhanced OER activity, implying that the Cu dopant has a crucial impact on boosting the reactivity by reducing the affinity of reaction intermediates. The enhancement could also be understood from the perspective of the electron structure characteristic through d-orbital resolved density of states (ORDOS) (d _{z ²} , d _xz , d _yz , d _xy , and d _{x ²-y ²} ) analysis. From the ORDOS analysis, we found an apparent alteration of the key orbitals between Co₂/N₄G (d _{z ²} , d _xz , and d _yz ) and CoCu/N₄G (d _z2, d _xz , d _yz , and d _xy ) with a substantial change in the overlap ratio (X _d). This theoretical study offers beneficial insights into developing a strategy for efficient OER catalysts utilizing a double-atom structure.

Polymer–Nickel Composite Filaments for 3D Printing of Open Porous Materials

Catalysis has been a key way of improving the efficiency-to-cost ratio of chemical and electrochemical processes. There have been recent developments in catalyst materials that enable the development of novel and more sophisticated devices that, for example, can be used in applications, such as membranes, batteries or fuel cells. Since catalytic reactions occur on the surface, most catalyst materials are based on open porous structures, which facilitates the transport of fluids (gas or liquid) and chemical (or electrochemical) specific surface activity, thus determining the overall efficiency of the device. Noble metals are typically used for low temperature catalysis, whereas lower cost materials, such as nickel, are used for catalysis at elevated temperatures. 3D printing has the potential to produce a more sophisticated fit for purpose catalyst material. This article presents the development, fabrication and performance comparison of three thermoplastic composites where PLA (polylactic acid), PVB (polyvinyl butyral) or ABS (acrylonitrile butadiene styrene) were used as the matrix, and nickel particles were used as filler with various volume fractions, from 5 to 25 vol%. The polymer–metal composites were extruded in the form of filaments and then used for 3D FDM (Fused Deposition Modeling) printing. The 3D printed composites were heat treated to remove the polymer and sinter the nickel particles. 3D printed composites were also prepared using nickel foam as a substrate to increase the final porosity and mechanical strength of the material. The result of the study demonstrates the ability of the optimized filament materials to be used in the fabrication of high open porosity (over 60%) structures that could be used in high-temperature catalysis and/or electrocatalysis.

Skeletal Nickel Catalyst for the Methanation Reaction Developed by Laser-Engineered Net-Shaping Technology

Here, we report a skeletal nickel catalyst prepared by cumulative processing. The Ni, Al, and CoCrMo multi-component alloys were printed by a dual-powder laser-engineered net-shaping system, and alloy samples with different components were obtained through high-throughput design. After leaching in 5 mol/L NaOH at 40 °C for 2 h, the specific surface area of the catalyst increased with increasing Al content. Increasing the leaching temperature and prolonging the leaching time also effectively increased the specific surface area of the catalyst. After leaching at 80 °C for 12 h, the specific surface area was 42.36 m2/g. After cleaning and hydrogen-reduction treatment at 400 °C, the catalyst showed high catalytic activity. The highest conversion rate of CO reached 89.56%, and the selectivity of CH4 remained above 98% for a long time.

3D printed nickel catalytic static mixers made by corrosive chemical treatment for use in continuous flow hydrogenation

Catalytic static mixers, 3D printed from nickel alloys, were treated with etching or leaching solutions to activate their surfaces for use in hydrogenation of alkenes, aldehydes and nitro-groups.

Synthesis of Silica-Based Solid-Acid Catalyst Material as a Potential Osteochondral Repair Model In Vitro

For osteochondral damage, the pH value change of the damaged site will influence the repair efficacy of the patient. For better understanding the mechanism of the acid-base effect, the construction of in vitro model is undoubtedly a simple and interesting work to evaluate the influence. Here, a novel porous silica-based solid-acid catalyst material was prepared by additive manufacturing technology, exhibiting improved eliminating effects of the residue. SEM, FTIR, and TGA were used to characterize the morphology, structure, and thermal stability of the synthesized 3D material. The reaction between 4-methoxybenzyl alcohol and 3, 4-dihydro-2H-pyran was used as a template reaction to evaluate the eliminating performance of the 3D porous material. Solvents were optimized, and three reaction groups in the presence of 3D SiO2, 3D SiO2-SO3H, and 3D SiO2-NH-SO3H, as well as one without catalyst, were compared. In addition, in consideration of the complicated situation of the physiological environment in vivo, universality of the synthesized 3D SiO2-NH-SO3H catalyst material was studied with different alcohols. The results showed that the sulfonic acid-grafted 3D material had excellent catalytic performance, achieving a yield over 95% in only 20 min. Besides, the catalyst material can be recycled at least 10 times, with yields still higher than 90%. Such a solid catalyst material is expected to have great potential in additive manufacturing because the catalyst material is easy-recyclable, renewable and biocompatible. The 3D material with connective channels may also be utilized as an in vitro model for environment evaluation of osteochondral repair in the future.

Binder-jetting 3D printer capable of voxel-based control over deposited ink volume, adaptive layer thickness, and selective multi-pass printing

The limited control over the printing process in commercial powder bed 3D printers hinders the exploration of novel materials and applications. In this study, a custom binder-jetting 3D printer was developed. The resulting fine-grained control over the printing process enables features such as voxel-based control over the printed ink volume, adaptive layer thickness, and selective multi-pass printing. A protocol was developed to optimize the 3D printing process for new build materials and binders, in which resolution tests were used as a guideline for improving the dimensional accuracy. As a demonstration of the voxel-based control over the printing process, a functionally graded object was printed.

High Performance Tunable Catalysts Prepared by Using 3D Printing

Honeycomb monoliths are the preferred supports in many industrial heterogeneous catalysis reactions, but current extrusion synthesis only allows obtaining parallel channels. Here, we demonstrate that 3D printing opens new design possibilities that outperform conventional catalysts. High performance carbon integral monoliths have been prepared with a complex network of interconnected channels and have been tested for carbon dioxide hydrogenation to methane after loading a Ni/CeO₂ active phase. CO₂ methanation rate is enhanced by 25% at 300 °C because the novel design forces turbulent flow into the channels network. The methodology and monoliths developed can be applied to other heterogeneous catalysis reactions, and open new synthesis options based on 3D printing to manufacture tailored heterogeneous catalysts.

Recent Advances in 3D Printing of Structured Materials for Adsorption and Catalysis Applications

Porous solids in the form of adsorbents and catalysts play a crucial role in various industrially important chemical, energy, and environmental processes. Formulating them into structured configurations is a key step toward their scale up and successful implementation at the industrial level. Additive manufacturing, also known as 3D printing, has emerged as an invaluable platform for shape engineering porous solids and fabricating scalable configurations for use in a wide variety of separation and reaction applications. However, formulating porous materials into self-standing configurations can dramatically affect their performance and consequently the efficiency of the process wherein they operate. Toward this end, various research groups around the world have investigated the formulation of porous adsorbents and catalysts into structured scaffolds with complex geometries that not only exhibit comparable or improved performance to that of their powder parents but also address the pressure drop and attrition issues of traditional configurations. In this comprehensive review, we summarize the recent advances and current challenges in the field of adsorption and catalysis to better guide the future directions in shape engineering solid materials with a better control on composition, structure, and properties of 3D-printed adsorbents and catalysts.

A Review on New 3-D Printed Materials' Geometries for Catalysis and Adsorption: Paradigms from Reforming Reactions and CO2 Capture

"Bottom-up" additive manufacturing (AM) is the technology whereby a digitally designed structure is built layer-by-layer, i.e., differently than by traditional manufacturing techniques based on subtractive manufacturing. AM, as exemplified by 3D printing, has gained significant importance for scientists, among others, in the fields of catalysis and separation. Undoubtedly, it constitutes an enabling pathway by which new complex, promising and innovative structures can be built. According to recent studies, 3D printing technologies have been utilized in enhancing the heat, mass transfer, adsorption capacity and surface area in CO2 adsorption and separation applications and catalytic reactions. However, intense work is needed in the field to address further challenges in dealing with the materials and metrological features of the structures involved. Although few studies have been performed, the promise is there for future research to decrease carbon emissions and footprint. This review provides an overview on how AM is linked to the chemistry of catalysis and separation with particular emphasis on reforming reactions and carbon adsorption and how efficient it could be in enhancing their performance.

Enabling intensification of multiphase chemical processes with additive manufacturing

Fixed bed supports of various materials (metal, ceramic, polymer) and geometries are used to enhance the performance of many unit operations in chemical processes. Consider first metal and ceramic monolith support structures, which are typically extruded. Extruded monoliths contain regular, parallel channels enabling high throughput because of the low pressure drop accompanying high flow rate. However, extruded channels have a low surface-area-to-volume ratio resulting in low contact between the fluid phase and the support. Additive manufacturing, also referred to as three dimensional printing (3DP), can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed including material-of-construction and total bed surface area, as well as accommodating system integration features compatible with continuous flow chemistry. These design parameters together with optimized extrinsic process conditions can be tuned to prepare customizable separation and reaction systems based on objectives for chemical process and/or the desired product. We discuss key elements of leveraging the flexibility of additive manufacturing to intensification with a focus on applications in continuous flow processes and disperse, multiphase systems enabling a range of scalable chemistry spanning discovery to manufacturing operations.

3D Printing in Heterogeneous Catalysis-The State of the Art

This paper describes the process of additive manufacturing and a selection of three-dimensional (3D) printing methods which have applications in chemical synthesis, specifically for the production of monolithic catalysts. A review was conducted on reference literature for 3D printing applications in the field of catalysis. It was proven that 3D printing is a promising production method for catalysts.

Monolith catalyst design via 3D printing: a reusable support for modern palladium-catalyzed cross-coupling reactions

The use of an additive manufacturing procedure for the modification of catalytic structures is currently gaining popularity in the field of catalysis.

3D printing in chemical engineering and catalytic technology: structured catalysts, mixers and reactors

Computer-aided fabrication technologies combined with simulation and data processing approaches are changing our way of manufacturing and designing functional objects. Also in the field of catalytic technology and chemical engineering the impact of additive manufacturing, also referred to as 3D printing, is steadily increasing thanks to a rapidly decreasing equipment threshold. Although still in an early stage, the rapid and seamless transition between digital data and physical objects enabled by these fabrication tools will benefit both research and manufacture of reactors and structured catalysts. Additive manufacturing closes the gap between theory and experiment, by enabling accurate fabrication of geometries optimized through computational fluid dynamics and the experimental evaluation of their properties. This review highlights the research using 3D printing and computational modeling as digital tools for the design and fabrication of reactors and structured catalysts. The goal of this contribution is to stimulate interactions at the crossroads of chemistry and materials science on the one hand and digital fabrication and computational modeling on the other.

Additive Manufacturing: Unlocking the Evolution of Energy Materials

The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.

Combining additive manufacturing and catalysis: a review

A review on additive manufacturing (AM) applied to heterogeneous catalysis reveals enabling power of AM and challenges to overcome in chemical interfacing and material printability.

Directed aerosol writing of ordered silica nanostructures on arbitrary surfaces with self-assembling inks

This paper reports the fabrication of micro- and macropatterns of ordered mesostructured silica on arbitrary flat and curved surfaces using a facile robot-directed aerosol printing process. Starting with a homogenous solution of soluble silica, ethanol, water, and surfactant as a self-assembling ink, a columnated stream of aerosol droplets is directed to the substrate surface. For deposition at room temperature droplet coalescence on the substrates and attendant solvent evaporation result in continuous, highly ordered mesophases. The pattern profiles are varied by changing any number of printing parameters such as material deposition rate, printing speed, and aerosol-head temperature. Increasing the aerosol temperature results in a decrease of the mesostructure ordering, since faster solvent evaporation and enhanced silica condensation at higher temperatures kinetically impede the molecular assembly process. This facile technique provides powerful control of the printed materials at both the nanoscale and microscale through chemical self-assembly and robotic engineering, respectively.

Robotic deposition of model hydroxyapatite scaffolds with multiple architectures and multiscale porosity for bone tissue engineering

Model hydroxyapatite (HA) scaffolds with porosities spanning multiple length scales were fabricated by robocasting, a solid freeform fabrication technique based on the robotic deposition of colloidal pastes. Scaffolds of various architectures including periodic, radial, and superlattice structures were constructed. Macropores (100-600 microm) were designed by controlling the arrangement and spacing between rods of HA. Micropores (1-30 microm) and submicron pores (less than 1 microm) were produced within the rods by including polymer microsphere porogens in the HA pastes and by controlling the sintering of the scaffolds. These model scaffolds may be used to systematically study the effects of scaffold porosity on bone ingrowth processes both in vitro and in vivo.

Effects of degradation and porosity on the load bearing properties of model hydroxyapatite bone scaffolds

Degradation of three types of model hydroxyapatite (HA) scaffolds was studied after in vitro degradation in a sodium acetate buffer (pH 4). Degradation was evaluated using compression testing, scanning electron microscopy (SEM), inductively coupled plasma (ICP) analysis, and weight measurements. Scaffolds were fabricated with a solid freeform fabrication (SFF) technique based on the robotic deposition of colloidal pastes. Scaffolds had a macrostructure resembling a lattice of rods. Scaffolds contained either macropores (270 or 680 microm in the x-y direction and 280 microm in the z-direction) and micropores (1-30-microm pores and pores <1 microm) or only macropores pores (270 microm in the x-y direction and 280 microm in the z-direction). A computer-aided design (CAD) program controlled the size and distribution of macropores; micropores were created by polymethylmethacrylate (PMMA) microsphere porogens (1-30-microm pore diameter) and controlled sintering (pores <1 microm). Percent weight loss of the scaffolds and calcium and phosphorus ion concentrations in solution increased as the degradation period increased for all scaffold types. After degradation, compressive strength and compressive modulus decreased significantly for those scaffolds with microporosity. For scaffolds without microporosity, the changes in strength and modulus after degradation were not statistically significant. The compressive strength of scaffolds without microporosity was significantly greater than the scaffolds with microporosity.