3D printing boosts membrane capability hopes

3D printing could advance membrane fabrication and capability, according to a new review by researchers from the University of Bath.

Membranes for the separation of gas or liquids are restricted mainly to tubular fibre or flat surface configurations due to current manufacturing processes. This results in a limited success rate of separation for certain properties.

Dr Darrell Patterson, from the University of Bath and co-author of the study, said: “This review is the first to explore the possibility and challenges of using 3D printing for producing separation membranes. Although 3D printing technology is not quite well enough developed to yet produce large scale membranes that will be cost competitive with existing products, this work does signal what the future possibilities are.”

The use of 3D printing techniques offers novel techniques that are able to produce membranes of different shapes and designs which can enable more precise membranes. These could include new membranes with bespoke pores and surface shapes that enhance micro-mixing and shear flow across membrane surfaces, reducing the energy and down-time associated with cleaning blockages and fouling of the membranes.

Dr Patterson said: “3D printing could produce membranes beyond that which are currently available, including controlled complex pore structures, integrated surface patterns and membranes based on nature."

Up to 15% of global energy use is for the separation and purification of products such as gases, fine chemicals and fresh water. Between 40 to 70% of chemical engineering industry capital and operating costs are also due to separation processes. Membrane technology could mean lower energy, more sustainable molecular separations that could be applied for gases and liquids.

The paper was published in the Journal of Membrane Science.