Design of 3D printing superhydrophilic pyramid-shaped porous materials for oil-in-water emulsion separation and visualization of separation mechanism

This study focuses on the design and fabrication of a superhydrophilic pyramid-shaped porous material using high-precision 3D printing technology for effective oil-in-water emulsion separation. The unique pyramid-shaped structure enhances droplet interception, significantly improving separation efficiency. The material’s surface was modified with a self-polymerized dopamine (DA) and polyethyleneimine (PEI) coating, resulting in superhydrophilic and underwater superoleophobicity. This porous material achieved a separation flux of 3098 L/m 2 h with a separation purity of 99.3 %. Computational Fluid Dynamics (CFD) simulations were employed to visualize the emulsion separation mechanism, providing insights into the dynamic process of droplet behavior within the funnel structure. The material also demonstrated excellent corrosion resistance, maintaining its performance after prolonged exposure to acidic, alkaline, and saline environments. These results suggest that the developed material offers a promising solution for high-efficiency oil–water separation with potential applications in environmental remediation and industrial wastewater treatment.