Fabricating a Structured Single-Atom Catalyst via High-Resolution Photopolymerization 3D Printing

This study introduces a novel solution to the design of structured catalysts, integrating single-piece 3D printing with single-atom catalysis. Structured catalysts are widely employed in industrial processes, as they provide optimal mass and heat transfer, leading to a more efficient use of catalytic materials. They are conventionally prepared using ceramic or metallic bodies, which are then washcoated and impregnated with catalytically active layers. However, this approach may lead to adhesion issues of the latter. By employing photopolymerization printing, a stable and active single-atom catalyst is directly shaped into a stand-alone, single-piece structured material. The battery of characterization methods employed in the present study confirms the uniform distribution of catalytically active species and the structural integrity of the material. Computational fluid dynamics simulations are applied to demonstrate enhanced momentum transfer and light distribution within the structured body. The materials are finally evaluated in the continuous-flow photocatalytic oxidation of benzyl alcohol to benzaldehyde, a relevant reaction to prepare biomass-derived building blocks. The innovative approach reported herein to manufacture a structured single-atom catalyst circumvents the complexities of traditional synthetic methods, offering scalability and efficiency improvements, and highlights the transformative role of 3D printing in catalysis engineering to revolutionize catalysts’ design.