Additive manufacturing has enabled realization of previously unproducible designs, such as intricate lattice networks, resulting in hierarchical porous materials of tunable properties. Such materials have demonstrated utility in heat exchangers, reaction vessels, structural scaffolds, biomedical implants, consumer products, and process intensification. Here, we investigate an assortment of lattice architectures in the context of fluid dynamics and mass transfer applications. Using a Carbon M1 3D printer, we produce lattice parts for experimental pressure studies with homogeneous and heterogeneous unit cell configurations. We examine how scaling of the unit cell and overall part geometry contribute to fluid phenomena within these ordered open cellular structures and present guidelines for designing lattice configurations. Experimentally measured pressure gradients through uniform cubic and Kelvin lattices at two sub-5 mm length scales, as well as combinations of each lattice configuration, are presented for pipes ranging from 12-52 mm diameter. We also demonstrate the potential for leveraging these porous materials for differential aerosol capture, with distinct filtration and spatial deposition modelling applications. Further, our results can be well described through a single predictive correlation across different lattice geometries and scales, establishing the design criteria needed to continue to translate these materials into process intensification applications. Together, these developments support the promise for tailor-made, multifunctional process components for a wide range of chemical engineering applications.

Scalable 3D printed lattices for control in fluid and aerosol applications

ACS Spring 2022

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