Performance-driven optimization of 3D-printed zeolite-based monoliths for carbon capture

This study presents a performance-driven approach to the optimization of 3D-printed monoliths based on 13X zeolite, obtained through Direct Ink Writing, aimed at carbon capture applications. The research compares three formulations using different binders - polyvinyl alcohol, sodium alginate, bentonite - evaluating their influence on printability, mechanical strength, and CO 2 capture performance. A comprehensive set of characterizations revealed the formulation-structure-performance relationships of the produced monoliths. A multi-criteria index was developed to rank the monoliths performance, highlighting the importance of tailoring ink composition to specific application requirements. Polyvinyl alcohol-based samples preserved the highest adsorption capacity but suffered from poor mechanical strength, while bentonite-based samples exhibited excellent structural integrity but lower diffusion performance. A fourth formulation obtained by using both alginate and bentonite showed the best compromise among all the properties studied. The proposed strategy enables rational design of 3D-printable materials for gas separation technologies and beyond.