Developing 3D-Printable Cathode Electrode for Monolithically Printed Microbial Fuel Cells (MFCs)

Ink-based additive manufacturing for electrochemical applications

Additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has drawn substantial attention in recent decades due to its efficiency and precise control in part fabrication. The limitations of conventional fabrication processes, especially regarding geometry complexity, supply chain, and environmental impact, have prompted the exploration of diverse AM technologies in electrochemistry. Especially, three ink-based AM techniques, binder jet printing (BJP), direct ink writing (DIW), and Inkjet Printing (IJP), have been extensively applied by numerous research teams to produce electrodes, catalyst scaffolds, supercapacitors, batteries, etc. BJP's versatility in utilizing a wide range of materials as powder feedstock promotes its potential for various electrode and battery applications. DIW and IJP stand out for their ability to handle multi-material manufacturing tasks and deliver high printing resolution. To capture recent advancements in this field, we present a comprehensive review of the applications of BJP, DIW, and IJP techniques in fabricating electrochemical devices and components. This review intends to provide an overview of the process-structure-property relationship in electrochemical materials and components across diverse applications manufactured using AM techniques. We delve into how the significantly improved design freedom over the structure offered by these ink-based AM techniques highlights the performance of electrochemical products. Moreover, we highlight their advantages in terms of material compatibility, geometry control, and cost-effectiveness. In specific cases, we also compare the performance of electrochemical components fabricated using AM and conventional manufacturing methods. Finally, we conclude this review article by offering some insights into the future development in this research field.

Current significance and future perspective of 3D-printed bio-based polymers for applications in energy conversion and storage system

The increasing global population has led to a surge in energy demand and the production of environmentally harmful products, highlighting the urgent need for renewable and clean energy sources. In this context, sustainable and eco-friendly energy production strategies have been explored to mitigate the adverse effects of fossil fuel consumption to the environment. Additionally, efficient energy storage devices with a long lifespan are also crucial. Tailoring the components of energy conversion and storage devices can improve overall performance. Three-dimensional (3D) printing provides the flexibility to create and optimize geometrical structure in order to obtain preferable features to elevate energy conversion yield and storage capacitance. It also serves the potential for rapid and cost-efficient manufacturing. Besides that, bio-based polymers with potential mechanical and rheological properties have been exploited as material feedstocks for 3D printing. The use of these polymers promoted carbon neutrality and environmentally benign processes. In this perspective, this review provides an overview of various 3D printing techniques and processing parameters for bio-based polymers applicable for energy-relevant applications. It also explores the advances and current significance on the integration of 3D-printed bio-based polymers in several energy conversion and storage components from the recently published studies. Finally, the future perspective is elaborated for the development of bio-based polymers via 3D printing techniques as powerful tools for clean energy supplies towards the sustainable development goals (SDGs) with respect to environmental protection and green energy conversion.

Structure evolution of air cathodes and their application in electrochemical sensor development and wastewater treatment

Cathode structure and material are the most important factors to determine the performance and cost of single chamber air-cathode microbial fuel cell (MFC), which is the most promising type of MFC technology. Since the first air cathode was invented in 2004, five major structures (1-layer, 2-layer, 3-layer, 4-layer and separator-support) have been invented and modified to fit new material, improve power performance and lower MFC cost. This paper reviewed the structure evolution of air cathodes in past 18 years. The benefits and drawbacks of these structures, in terms of power generation, material cost, fabrication procedure and modification process are analyzed. The practical application cases (e.g., sensor development and wastewater treatment) employed with different cathode structures were also summarized and analyzed. Based on practical performance and long-term cost analysis, the 2-layer cathode demonstrated much greater potential over other structures. Compared with traditional activated-sludge technology, the cost of an MFC-based system is becoming competitive when employing with 2-layer structure. This review not only provides a detailed development history of air cathode but also reveals the advantages/disadvantages of air cathode with different structures, which will promote the research and application of air-cathode MFC technology.

Immobilization of photocatalytic materials for (waste)water treatment using 3D printing technology - advances and challenges

Photocatalysis has been considered a promising technology for the elimination of a wide range of pollutants in water. Various types of photocatalysts (i.e., homojunction, heterojunction, dual Z-scheme photocatalyst) have been developed in recent years to address the drawbacks of conventional photocatalysts, such as the large energy band gap and rapid recombination rate of photogenerated electrons and holes. However, there are still challenges in the design of photocatalytic reactors that limit their wider application for real (waste)water treatment, such as difficulties in their recovery and reuse from treated (waste)waters. 3D printing technologies have been introduced very recently for the immobilization of materials in novel photocatalytic reactor designs. The present review aims to summarize and discuss the advances and challenges in the application of various 3D printing technologies (i.e., stereolithography, inkjet printing, and direct ink writing) for the fabrication of stable photocatalytic materials for (waste)water treatment purposes. Furthermore, the limitations in the implementation of these technologies to design future generations of photocatalytic reactors have been critically discussed, and recommendations for future studies have been presented.

3D Composite PDMS/MWCNTs Aerogel as High-Performing Anodes in Microbial Fuel Cells

Porous 3D composite materials are interesting anode electrodes for single chamber microbial fuel cells (SCMFCs) since they exploit a surface layer that is able to achieve the correct biocompatibility for the proliferation of electroactive bacteria and have an inner charge transfer element that favors electron transfer and improves the electrochemical activity of microorganisms. The crucial step is to fine-tune the continuous porosity inside the anode electrode, thus enhancing the bacterial growth, adhesion, and proliferation, and the substrate's transport and waste products removal, avoiding pore clogging. To this purpose, a novel approach to synthetize a 3D composite aerogel is proposed in the present work. A 3D composite aerogel, based on polydimethylsiloxane (PDMS) and multi-wall carbon nanotubes (MWCNTs) as a conductive filler, was obtained by pouring this mixture over the commercial sugar, used as removable template to induce and tune the hierarchical continuous porosity into final nanostructures. In this scenario, the granularity of the sugar directly affects the porosities distribution inside the 3D composite aerogel, as confirmed by the morphological characterizations implemented. We demonstrated the capability to realize a high-performance bioelectrode, which showed a 3D porous structure characterized by a high surface area typical of aerogel materials, the required biocompatibility for bacterial proliferations, and an improved electron pathway inside it. Indeed, SCMFCs with 3D composite aerogel achieved current densities of (691.7 ± 9.5) mA m^-2, three orders of magnitude higher than commercial carbon paper, (287.8 ± 16.1) mA m^-2.

Paper-based platforms for microbial electrochemical cell-based biosensors: A review

The development of low-cost analytical devices for on-site water quality monitoring is a critical need, especially for developing countries and remote communities in developed countries with limited resources. Microbial electrochemical cell-based (MXC) biosensors have been quite promising for quantitative and semi-quantitative (often qualitative) measurements of various water quality parameters due to their low cost and simplicity compared to traditional analytical methods. However, conventional MXC biosensors often encounter challenges, such as the slow establishment of biofilms, low sensitivity, and poor recoverability, making them unable to be applied for practical cases. In response, MXC biosensors assembled with paper-based materials demonstrated tremendous potentials to enhance sensitivity and field applicability. Furthermore, the paper-based platforms offer many prominent features, including autonomous liquid transport, rapid bacterial adhesion, lowered resistance, low fabrication cost (<$1 in USD), and eco-friendliness. Therefore, this review aims to summarize the current trend and applications of paper-based MXC biosensors, along with critical discussions on their field applicability. Moreover, future advancements of paper-based MXC biosensors, such as developing a novel paper-based biobatteries, increasing the system performance using an unique biocatalyst, such as yeast, and integrating the biosensor system with other advanced tools, such as machine learning and 3D printing, are highlighted.

State-of-the-art of 3D printing technology of alginate-based hydrogels-An emerging technique for industrial applications

Recently, three-dimensional (3D) printing (also known as additive manufacturing) has received unprecedented consideration in various fields owing to many advantages compared to conventional manufacturing equipment such as reduced fabrication time, one-step production, and the ability for rapid prototyping. This promising technology, as the next manufacturing revolution and universal industrial method, allows the user to fabricate desired 3D objects using a layer-by-layer deposition of material and a 3D printer. Alginate, a versatile polysaccharide derived from seaweed, is popularly used for this advanced bio-fabrication technique due to its printability, biodegradability, biocompatibility, excellent availability, low degree of toxicity, being a relatively inexpensive, rapid gelation in the presence of Ca²⁺ divalent, and having fascinating chemical structure. In recent years, 3D printed alginate-based hydrogels have been prepared and used in various fields including tissue engineering, water treatment, food, electronics, and so forth. Due to the prominent role of 3D printed alginate-based materials in diverse fields. So, this review will focus and highlight the latest and most up-to-date achievements in the field of 3D printed alginate-based materials in biomedical, food, water treatment, and electronics.

Customizable design strategies for high-performance bioanodes in bioelectrochemical systems

Bioelectrochemical systems (BESs) can fulfill the demand for renewable energy and wastewater treatment but still face significant challenges to improve their overall performance. Core efforts have been made to enhance the bioelectrode performance, yet, previous approaches are fragmented and have limited applicability, unable to flexibly adjust physicochemical and structural properties of electrodes for specific requirements in various applications. Here, we propose a facile electrode design strategy that integrates three-dimensional printing technology and functionalized modular electrode materials. A customized graphene-based electrode with hierarchical pores and functionalized components (i.e., ferric ions and magnetite nanoparticles) was fabricated. Owing to efficient mass and electron transfer, a high volumetric current density of 10,608 ± 1,036 A/m³ was achieved, the highest volumetric current density with pure Geobacter sulfurreducens to date. This strategy can be readily applied to existing BESs (e.g., microbial fuel cells and microbial electrosynthesis) and provide a feasibility for practical application.

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A 3D-printed graphene aerogel electrode was proposed for BESs

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The optimized electrode mass transfer resistance was less than 5% of carbon felt

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A high volumetric current density of 10,608 ± 1,036 A/m³ was achieved