WashU researchers turn carbon dioxide into advanced 3D-printed materials

Carbon dioxide (CO₂) emissions are a major cause of climate change and its various effects on ecosystems, weather patterns, and human societies. Despite international efforts to curb emissions, the rising concentration of CO₂ in the atmosphere highlights the need for innovative solutions that go beyond reduction — transforming the problem into an opportunity.

Researchers at Washington University in St. Louis have developed an innovative process to convert CO₂ into valuable carbon-based solid materials. Feng Jiao, professor of energy, environmental & chemical engineering in the McKelvey School of Engineering, along with Kelvin Fu, assistant professor at the University of Delaware, introduces an integrated electrocatalytic-thermocatalytic system capable of converting CO₂ into carbon nanotubes (CNTs) to produce high-quality 3D-printed carbon nanocomposites.

“We are trying to convert CO₂-derived carbon material into functional materials, like carbon nanotubes. Eventually, we want to incorporate these into filaments that can be used for 3D printing,” Jiao said. “This project offers a way to address CO₂ emissions while producing valuable materials needed for various industries.”

The team’s process begins with an anion exchange membrane CO₂ electrolyzer, which operates under ambient conditions to convert CO₂ into carbon monoxide (CO). The CO is then processed in a thermochemical reactor to produce CNTs. These CNTs are incorporated into advanced 3D printing processes, enabling the production of carbon nanocomposites with enhanced mechanical properties.

“The CNTs we produce from CO₂ are of comparable quality to those manufactured through conventional processes. This opens opportunities for industries to adopt more sustainable practices without compromising material performance,” Jiao said.

The carbon nanocomposites created from these CNTs have transformative potential across different industries. For example, in construction, these composites can replace traditional high-emission materials like steel, providing a more sustainable alternative for structural reinforcement, paneling, and the repair of stressed infrastructure. In transportation, the lightweight property of carbon nanocomposites makes them ideal for producing components in automobiles, aerospace and marine vehicles, reducing weight and improving fuel efficiency.

Looking ahead, Jiao sees significant potential for applying this technology in space exploration, particularly on Mars.

“Mars’ atmosphere is 95% CO₂,” Jiao said. “If we can build a habitat on the surface of Mars, in principle, it is possible to convert CO₂ into oxygen and carbon nanotubes. Oxygen will be used to support astronauts, and the carbon material can be used for 3D printing and construction on the surface of Mars.” 

More about Jiao’s research can be found in Nature Communications published Dec. 4, 2024.

Crandall BS, Naughton M, Park S, Yu J, Zhang C, Mahtabian S, Wang K, Liang X, Fu K, Jiao F. Transforming CO₂ into advanced 3D printed carbon nanocomposites. Nature Communications, Dec. 4, 2024. DOI: https://doi.org/10.1038/s41467-024-54957-w

This material is based upon work supported by the U.S. Department of Energy under Award Number DE-FE0032147.

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