3D printing for safe organic synthesis in mixed liquid/gas-phase chemistry

Working with liquid/gas-phase systems in chemical laboratories is a fundamentally important but difficult operation, mainly due to the explosion risk associated with conventional laboratory equipment. Such systems, in the case of improper operation or destruction, may pose a significant threat to researchers. To address this challenge, our work explores the potential of additive technologies, particularly fused filament fabrication (FFF), for improving laboratory safety. We have successfully utilized FFF to produce compact safety modules, including integrated bursting discs, which can be easily made on demand and adapted to various types of reaction setups. Compared with traditional glassware, these modules, when integrated with laboratory reactors, significantly enhance operational safety. Our research highlights that in the event of excessive internal pressure, 3D-printed reactor parts undergo delamination and cracking of the wall, a mechanism that notably avoids the creation of hazardous fragments from the whole reaction vessel. This study demonstrated the efficiency and safety of additively manufactured reactors in organic synthesis using a variety of gases, including acetylene, carbon dioxide, and hydrogen. We systematically tested these reactors in vinylation and azide–alkyne cycloaddition reactions. Our findings confirm that 3D-printed reactors not only provide increased safety during pressurized operations but also maintain operational efficiency. The discussed approach offers a transformative solution for safer and more effective handling of gaseous reagents in laboratory settings, marking a significant advancement in flexible reactor design and chemical laboratory safety practices.