In a groundbreaking development that could revolutionize the energy sector, researchers at Xi’an Jiaotong University have unveiled a novel approach to 3D printing titanium scaffolds with multiscale porous structures. Led by Guangbin Zhao from the State Key Laboratory for Manufacturing System Engineering, the team has successfully combined digital light processing (DLP) 3D printing with acrylic–titanium composite powders to create highly porous, yet robust, titanium scaffolds. These scaffolds are poised to significantly enhance applications requiring large specific surface areas, such as energy storage and conversion devices.
The innovation lies in the powder modification process, where titanium powders are composited with acrylic resin. This modification not only maintains the spherical shape of the powders but also enhances the stability and curing characteristics of the slurry. As Zhao explains, “The depth sensitivity of the modified powder slurries with 45 vol% solid loading increased by approximately 72%. This improvement is crucial for achieving the desired porous structures.”
The resulting scaffolds feature macropores with diameters of approximately 1 mm and internal open micropores ranging from 5.7 to 13.0 μm. Despite their high porosity of around 73.95%, these scaffolds exhibit impressive compressive strength, measuring (70.01 ± 3.53) MPa. This strength-to-porosity ratio is a game-changer for industries seeking lightweight, high-performance materials.
The implications for the energy sector are vast. Porous titanium scaffolds with such high specific surface areas can enhance the efficiency of energy storage devices like batteries and supercapacitors. The customization potential of 3D printing allows for tailored designs that can optimize energy conversion processes, leading to more efficient and sustainable energy solutions.
The research, published in the International Journal of Extreme Manufacturing, opens up new avenues for material science and engineering. As Zhao and his team continue to refine their technique, the potential for commercial applications in the energy sector becomes increasingly tangible. This breakthrough could pave the way for lighter, more efficient energy storage and conversion systems, driving innovation in renewable energy technologies.