As global concerns over emerging contaminants (such as pharmaceuticals) in wastewater grow, traditional treatment methods like ozone oxidation and activated carbon adsorption face limitations—from high energy consumption to reliance on critical raw materials. Now, a collaborative team of researchers from Gdansk University of Technology (Poland), Università Politecnica delle Marche (Italy), and Lund University (Sweden) has developed a game-changing solution: 3D-printed boron-nitrogen (B,N)-doped carbon electrodes fabricated via a synergistic combination of 3D printing, phase inversion, and microwave plasma-enhanced chemical vapor deposition (MPECVD). Published in Nano-Micro Letters , this technology delivers unprecedented performance in electrochemical oxidation (EO) of persistent pollutants, offering a scalable, metal-free path to sustainable water treatment.
Why These 3D-Printed Electrodes Stand Out
The core innovation lies in the integration of topology optimization, precision fabrication, and catalyst-free nanostructure growth—addressing key pain points in wastewater treatment while boosting efficiency:
Key Design, Fabrication, and Performance Details
1. Topology Optimization via CFD Simulation
To maximize efficiency, the team tested 15 modular geometries (6 TPMS and 2 fractal structures) using CFD, focusing on three critical metrics: mixing efficiency, pressure drop, and surface area-to-volume ratio.
2. Precision Fabrication: From 3D Printing to MPECVD
The fabrication process combines three scalable techniques to create hierarchical porosity at micro- and nanoscales:
3. Electrochemical Performance & Pollutant Degradation
Critical Material Properties
β-Blocker Degradation Results
In flow-through reactors, the electrodes targeted three common β-blockers (atenolol, metoprolol, propranolol), with key findings:
Future Outlook & Sustainability Impact
This technology addresses two critical goals for wastewater treatment: performance and sustainability. By eliminating metal catalysts, using low-cost PAN as a precursor, and leveraging scalable 3D printing, the electrodes reduce reliance on critical raw materials (e.g., rare metals in conventional catalysts) and cut fabrication costs by 30% compared to boron-doped diamond electrodes.
Looking ahead, the team aims to:
With the EU’s new Urban Wastewater Directive mandating removal of organic micropollutants, these 3D-printed electrodes offer a timely, scalable solution—bridging advanced materials science and practical environmental engineering.
Stay tuned for further innovations from this team as they advance toward commercializing this sustainable water treatment technology!
Nano-Micro Letters
Experimental study
3D‑Printed Boron‑Nitrogen Doped Carbon Electrodes for Sustainable Wastewater Treatment via MPECVD
24-Jun-2025