Revolutionizing Monolithic Catalysts: The Breakthroughs of Design Control through Computer-Aided-Manufacturing

Additive manufacturing (AM) presents a promising opportunity for the innovative design and production of structured catalytic materials. Given the critical role of catalysts in industrial catalytic processes, AM has the potential to contribute to the development of improved catalysts by reducing activation energy and enhancing selectivity. Conventional synthesis methods limit the choice of structural materials and composition for producing monoliths. Additionally, the deposition of catalytic compounds is also restricted by commonly applied techniques that may require prior coverage or treatments to improve adherence or do not achieve a homogenous coat. Moreover, production is limited to monoliths with straight and parallel channels. However, this format drives to laminar regime flow thus restricting the radial mass and heat transfer. Conversely, AM allows the production of a wider variety of compositions and more complex structures that have proven to rise their effectiveness by increasing reagents-catalyst interaction, making catalytic processes more cost-effective. Therefore, in this review an outline of the recent progress of AM methods in the development of monolithic catalysts is presented focusing on the requirements, advantages, and disadvantages of each technique, hence providing a practical overview of their novel opportunities to overcome current limitations in catalyst synthesis. Additive manufacturing (AM) offers potential for designing structured catalytic materials, enhancing industrial processes. AM can improve catalysts by reducing activation energy and enhancing selectivity. Traditional methods limit material choice and coating uniformity. AM enables diverse compositions and complex structures, enhancing reagent-catalyst interactions, and cost-effectiveness. This review outlines AM's progress in developing monolithic catalysts, discussing advantages, disadvantages, and opportunities to overcome synthesis limitations. image