One-step calcination strategy of 3D printing CuO–ZnO–ZrO2 catalysts for CO2 hydrogenation using digital light processing (DLP)

Abstract

CuO–ZnO–ZrO₂ catalyst attracted significant attention for CO₂ hydrogenation to methanol. Gyroid-based triply period minimal surface lattice structures feature highly ordered porous networks, which could be used to enhance catalytic performance and efficiency. This paper presents a formulating and one-step calcination strategy that united the removal of polymer resin and calcination of catalyst precursor at one temperature. This enabled 3D printing gyroid-structured CuO–ZnO–ZrO₂ catalyst for CO₂ hydrogenation while minimizing the impact of overheating on the catalyst performance. A photocurable formulation loaded with CuO–ZnO–ZrO₂ precursor was developed. Using the optimized formulation, gyroid structures with varying pore sizes were successfully printed and calcined. The optimal lattice wall thickness that balances porosity and structural stability was identified. The results indicate that the resin used for 3D printing was successfully removed at a lower temperature and the catalytic activity of the 3D-printed structured catalyst was retained through the one-step calcination process while the gyroid lattice geometry can enhance catalytic efficiency than cylindrical structure.