Three-Dimensionally Printed Catalytic Structures

Three-dimensionally (3D)-printed catalytic structures are revolutionizing catalysis and chemical engineering. Unlike traditional supports, modern triply periodic minimal surfaces (TPMS), lattices, and fractals actively influence mass and heat transfer and flow distribution. This review summarizes advancements in the classification, design, fabrication, and application of 3D-printed catalysts over the past decade. The article covers various constructive types (supports, integrated phases, multifunctional reactors) and materials (polymers, ceramics, metals, hybrids), along with fabrication techniques compliant with ISO/ASTM standards (FDM, SLA, DIW, SLM, EBM). It emphasizes post-processing and functionalization strategies (impregnation, calcination, sulfonation) and characterization tools (SAXS, CT, synchrotron-based techniques). A critical comparison highlights advantages, including tunable geometry, improved hydrodynamics, lower pressure drop, enhanced durability, and reproducibility. Three-dimensionally printed catalysts are an interdisciplinary platform combining materials science, chemical engineering, and digital manufacturing. They hold promise for sustainable chemistry, modular production, CO2 utilization, photocatalysis, and biocatalysis, making them a key innovation for future catalytic reactors.