ValCUN’s 3D printed catalytic air purifier reduces emissions and costs

Poor air quality from industrial emissions has a significant impact on public health, leading to problems like strokes, heart disease, and respiratory conditions. For this reason, efforts are being made to develop air purification systems for industrial users that are at once effective, cost efficient, and easy to integrate. Such is the mission at AddCat, a Dutch startup that develops 3D printed metal catalysts capable of purifying air in industries like food, biogas, and chemical and solvent processing. Recently, AddCat teamed up with ValCUN, a specialist in single-step metal AM, to develop a next-gen catalytic reactor with higher conversion efficiency and a 37% lower total cost of ownership.

The air purification system combines a 3D printed aluminum substrate with catalytic materials, and relies on a chemical process called catalytic oxidation to convert harmful emissions into clean air. By leveraging ValCUN’s proprietary Molten Metal Deposition (MMD) technology, the partners have been able to overcome some challenges typical of catalytic air purification, including high costs (driven by the use of rare metals like palladium) and limited design freedom (associated with traditional manufacturing methods). MMD in particular also unlocked benefits compared to other metal AM processes like LPBF and binder jetting, including the use of aluminum and lower overall costs.

In fact, the use of aluminum to manufacture the air purification system has been critical to the product’s success. The metal, known for its high thermal conductivity, actually increases the conversion rate of harmful emissions at a lower operating temperature. This translates to an air purification system that is more efficient and consumes less catalytic material.

In combination with ValCUN’s MMD process—a single-step extrusion process that uses wire feedstock—the partners have maximized the benefits of aluminum for this application. In this use case, ValCUN points to three key advantages that its technology offers: support-free printing of the catalytic reactor for faster turnarounds; raster-like surface finishes, which improve catalytic coating adhesion; and the ability to print the aluminum substrate, which enables weight reduction and improves heat transfer.

In tests comparing the 3D printed catalytic air purification system to a conventional reactor and AddCat’s original design, the results were undeniable. The 3D printed aluminum reactor showcased higher conversion efficiency, a 4x reduction in substrate manufacturing costs, and a 37% lower total cost of ownership per year.

Part of this economic efficiency is the result of the fact that the 3D printed reactor can be recycled. As ValCUN writes on its blog: “After a 10-year reactor lifespan, the catalytic materials can be recovered, unlike traditional systems that typically degrade after just three years. This feature enables up to 30% CAPEX recovery—a massive leap in sustainability and cost-effectiveness.”

Ultimately, ValCUN’s MMD process offers an alternative method for manufacturing more efficient catalytic air purification systems. The benefits unlocked by this production process can help industries ramp up their emissions reduction strategies in a way that is circular and lower cost.