Custom-Shaped Carbon Xerogel Materials by 3D Printing

Sol–gel-based carbon xerogels possess very promising properties for pollution abatement,
using processes that associate adsorption and on-site electrochemical oxidation. However, combining
a high exterior surface area (for efficient diffusion) and a monolithic shape (necessary for electrochemical
processes) poses challenges. In this work, the shape of monolithic carbon xerogels was
contrived by the use of 3D-printed molds. Several parameters were optimized: the choice of mold
design, the choice of plastic, the 3D printer parameters, the solvent, and the process of dissolving the
plastic. A design combining fine sticks and plates made of ABS was printed; a sol–gel carbon xerogel
monolith was synthesized in it, and the mold was removed by using a combination of acetone and
pyrolysis. Dissolving the plastic could be carried out by placing the material on a metallic net and
leaving the dissolved ABS to settle. The resulting carbon material exhibits a high exterior surface
area and good strength, leading to potential uses in the aforementioned process. The research shows
that 3D printing is an efficient method of parameter optimization in pre-industrialization research,
thanks to its flexibility, low cost, and ease of use.