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

Polymers in 3D printing of external maxillofacial prostheses and in their retention systems

Maxillofacial defects, arising from trauma, oncological disease or congenital abnormalities, detrimentally affect daily life. Prosthetic repair offers the aesthetic and functional reconstruction with the help of materials mimicking natural tissues. 3D polymer printing enables the design of patient-specific prostheses with high structural complexity, as well as rapid and low-cost fabrication on-demand. However, 3D printing for prosthetics is still in the early stage of development and faces various challenges for widespread use. This is because the most suitable polymers for maxillofacial restoration are soft materials that do not have the required printability, mechanical strength of the printed parts, as well as functionality. This review focuses on the challenges and opportunities of 3D printing techniques for production of polymer maxillofacial prostheses using computer-aided design and modeling software. Review discusses the widely used polymers, as well as their blends and composites, which meet the most important assessment criteria, such as the physicochemical, biological, aesthetic properties and processability in 3D printing. In addition, strategies for improving the polymer properties, such as their printability, mechanical strength, and their ability to print multimaterial and architectural structures are highlighted. The current state of the prosthetic retention system is presented with a focus on actively used polymer adhesives and the recently implemented prosthesis-supporting osseointegrated implants, with an emphasis on their creation from 3D-printed polymers. The successful prosthetics is discussed in terms of the specificity of polymer materials at the restoration site. The approaches and technological prospects are also explored through the examples of the nasal, auricle and ocular prostheses, ranging from prototypes to end-use products.

Shaping of Porous CeO2 Powders into Highly Active Catalyst Carriers

CeO₂ is attracting more and more attention because of its outstanding performance in heterogeneous catalysis, as an active support and a reaction promoter in reactions of industrial interest. We herein describe a novel and scalable manufacturing process of mm-sized CeO₂ spheres by a combination of extrusion and spheronization of CeO₂ porous powders. In this study, wet paste formulation and fabrication procedures were optimized, and as a result methylcellulose was identified as the best plasticizer for paste extrusion to provide well-defined spherical shapes and smooth surfaces, as well as reproducible batches. After nickel impregnation (10 wt %), the catalytic performance of CeO₂ supports was evaluated in the CO₂ methanation reaction (T = 250-350 °C, P = 5 bar·g) and compared with that of commercial Al₂O₃ spheres doped or not with CeO₂. These novel CeO₂-based catalysts are easily reduced at a moderate temperature and more active than the Al₂O₃ analogues, particularly at low reaction temperatures and small reactor volumes, properties that make their implementation in emerging reactor configurations very promising.

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.

Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

The aim of this work is to evaluate the performance of the stirring 3D Fe/Al2O3 monolithic reactor in batch operation applied to the liquid-phase hydroxylation of phenol by hydrogen peroxide (H2O2). An experimental and numerical investigation was carried out at the following operating conditions: CPHENOL,0 = 0.33 M, CH2O2,0 = 0.33 M, T = 75–95 °C, P = 1 atm, ω = 200–500 rpm and WCAT ~ 1.1 g. The kinetic model described the consumption of the H2O2 by a zero-order power-law equation, while the phenol hydroxylation and catechol and hydroquinone production by Eley–Rideal model; the rate determining step was the reaction between the adsorbed H2O2, phenol in solution with two active sites involved. The 3D CFD model, coupling the conservation of mass, momentum and species together with the reaction kinetic equations, was experimentally validated. It demonstrated a laminar flow characterized by the presence of an annular zone located inside and surrounding the monoliths (u = 40–80 mm s−1) and a central vortex with very low velocities (u = 3.5–8 mm s−1). The simulation study showed the increasing phenol selectivity to dihydroxybenzenes by the reaction temperature, while the initial H2O2 concentration mainly affects the phenol conversion.

Ti(C,N) and WC-Based Cermets: A Review of Synthesis, Properties and Applications in Additive Manufacturing

In recent years, the use of cermets has shown significant growth in the industry due to their interesting features that combine properties of metals and ceramics, and there are different possible types of cermets, depending on their composition. This review focuses on cemented tungsten carbides (WC), and tungsten carbonitrides (WCN), and it is intended to analyze the relationship between chemical composition and processing techniques of these materials, which results in their particular microstructural and mechanical properties. Moreover, the use of cermets as a printing material in additive manufacturing or 3D printing processes has recently emerged as one of the scenarios with the greatest projection, considering that they manufacture parts with greater versatility, lower manufacturing costs, lower raw material expenditure and with advanced designs. Therefore, this review compiled and analyzed scientific papers devoted to the synthesis, properties and uses of cermets of TiC and WC in additive manufacturing processes reported thus far.

Zeolites on 3D-printed open metal framework structure: metal migration into zeolite promoted catalytic cracking of endothermic fuels for flight vehicles

Selective laser melting printed metal lattice structures functionalised using zeolites have been shown as a promising new generation of catalysts. The unprecedented catalytic activity can be explained by metal migration (most likely chromium) from the support into the zeolite phase making it a promising candidate for endothermic fuels for high-speed flight vehicles.

Manufacturing and Application of 3D Printed Photo Fenton Reactors for Wastewater Treatment

Additive manufacturing (AM) or 3D printing offers a new paradigm for designing and developing chemical reactors, in particular, prototypes. The use of 3D printers has been increasing, their performance has been improving, and their price has been reducing. While the general trend is clear, particular applications need to be assessed for their practicality. This study develops and follows a systematic approach to the prototyping of Advanced Oxidation Processes (AOP) reactors. Specifically, this work evaluates and discusses different printable materials in terms of mechanical and chemical resistance to photo-Fenton reactants. Metallic and ceramic materials are shown to be impracticable due to their high printing cost. Polymeric and composite materials are sieved according to criteria such as biodegradability, chemical, thermal, and mechanical resistance. Finally, 3D-printed prototypes are produced and tested in terms of leakage and resistance to the photo-Fenton reacting environment. Polylactic acid (PLA) and wood-PLA composite (Timberfill^®) were selected, and lab-scale raceway pond reactors (RPR) were printed accordingly. They were next exposed to H2O2/Fe(II) solutions at pH = 3 ± 0.2 and UV radiation. After 48 h reaction tests, results revealed that the Timberfill^® reactor produced higher Total Organic Carbon (TOC) concentrations (9.6 mg·L^-1) than that obtained for the PLA reactor (5.5 mg·L^-1) and Pyrex^® reactor (5.2 mg·L^-1), which suggests the interference of Timberfill^® with the reaction. The work also considers and discusses further chemical and mechanical criteria that also favor PLA for 3D-printing Fenton and photo-Fenton reactors. Finally, the work also provides a detailed explanation of the printing parameters used and guidelines for preparing prototypes.

Well-Ordered 3D Printed Cu/Pd-Decorated Catalysts for the Methanol Electrooxidation in Alkaline Solutions

In this article, a method for the synthesis of catalysts for methanol electrooxidation based on additive manufacturing and electroless metal deposition is presented. The research work was divided into two parts. Firstly, coatings were obtained on a flat substrate made of light-hardening resin dedicated to 3D printing. Copper was deposited by catalytic metallization. Then, the deposited Cu coatings were modified by palladium through a galvanic displacement process. The catalytic properties of the obtained coatings were analyzed in a solution of 0.1 M NaOH and 1 M methanol. The influence of the deposition time of copper and palladium on the catalytic properties of the coatings was investigated. Based on these results, the optimal parameters for the deposition were determined. In the second part of the research work, 3D prints with a large specific surface were metallized. The elements were covered with a copper layer and modified by palladium, then chronoamperometric curves were determined. The application of the proposed method could allow for the production of elements with good catalytic properties, complex geometry with a large specific surface area, small volume and low weight.