Masked stereolithography and polymerization induced phase separation for 3D printing of membranes.

Conventional polymeric membrane manufacturing faces significant limitations, including reliance on harsh chemicals, limited geometrical shapes (primarily flat sheets and hollow fibers), low resolution, and slow production speeds. This study introduces an innovative approach for 3D printing complex-shaped membranes with tailored properties, utilizing polymerization-induced phase separation (PIPS) and masked stereolithography (MSLA). The influence of processing parameters, including resin volume, irradiation duration, and temperature, on membrane characteristics-such as pore size, porosity, thickness, surface morphology, water permeability, and rejection rate- is systematically investigated. The findings indicate that this method can fabricate membranes with a wide range of pore sizes and porosities. The membrane architecture comprises interconnected nodules, the dimensions of which are contingent upon the processing conditions. Furthermore, the study demonstrates that PIPS facilitates the phase inversion of thermosets and the incorporation of environmentally friendly biobased solvents, thereby broadening the scope of membrane fabrication with novel polymers.