3D-printed spacers integrated with module vibration for enhanced ultrafiltration permeability and antifouling

Abstract The incorporation of 3D-printed spacers into membrane filtration systems has recently emerged as a promising strategy for enhancing filtration performance and mitigating membrane fouling. This study integrated four 3D-printed spacer designs into a vibratory cross-flow ultrafiltration system to evaluate their combined effect with module vibration on dairy wastewater treatment. System performance was assessed using key indicators, including permeate flux, COD retention, total membrane resistance, and specific energy consumption. Results showed that PETG -based spacers, particularly the conical design, increased permeate flux by up to 300% relative to the control, with fourfold flux enhancements achieved when combined with module vibration. COD retention improved modestly across most configurations, while total resistance was consistently reduced by approximately 76 to 85% relative to the control, with the greatest decrease observed for the conical spacer under high-vibration conditions. Energy analysis further confirmed that combining 3D-printed spacers with module vibration was the most efficient operating strategy, markedly lowering specific energy consumption relative to the control. Overall, the conical and reinforced branched spacer designs operated under high vibration achieved the best overall balance of flux enhancement, resistance reduction, and energy efficiency, highlighting their potential for sustainable, low-fouling ultrafiltration applications.