Vat Photopolymerization of High-Solid content UV-curable Resins for Low-Temperature Sintered Ceramic Catalyst Scaffolds

This study addresses the challenge of fabricating high-performance ceramic catalyst scaffolds with complex geometries and optimized properties by introducing an innovative approach using vat photopolymerization 3D printing of high-solid content UV-curable resins. This method enables the creation of a ceramic catalysts with tailored geometries, hierarchical porosities, and enhanced catalytic performances. Composite slurries containing up to 50 wt.% ceramic powders (pseudo-boehmite, halloysite nanotubes, and CeO 2 ) were developed and optimized for digital light processing (DLP) 3D printing, with fine-tuned rheological properties to enable the printing of complex 3D structures with deflection angle topologies. Low-temperature sintering at 600°C yielded crack-free monolithic catalysts with a high specific surface area (112.45 m 2 /g) and hierarchical porosity. The 3D printed CeO 2 /γ-Al 2 O 3 -HNTs catalysts demonstrated exceptional photocatalytic performance for tetracycline degradation, achieving 92.7% removal within 2 h, with the 3D printed topology significantly enhancing mass transfer and light utilization compared to conventional powder or honeycomb catalysts. This facile approach enables precise control over the catalyst geometry and composition, offering a versatile platform for designing advanced functional ceramic materials for environmental remediation and catalysis applications. This study highlights the potential of 3D printing technology to revolutionize catalyst design and manufacturing, paving the way for more efficient and tailored catalytic systems.