Continuous Volumetric 3D Printing: Xolography in Flow.

Additive manufacturing techniques continue to improve in resolution, geometrical freedom, and production rates, expanding their application range in research and industry. Most established techniques, however, are based on layer-by-layer polymerization processes, leading to an inherent trade-off between resolution and printing speed. Volumetric 3D printing enables the polymerization of freely defined volumes allowing the fabrication of complex geometries at drastically increased production rates and high resolutions, marking the next chapter in light-based additive manufacturing. This work advances the volumetric 3D printing technique xolography to a continuous process. Dual-color photopolymerization is performed in a continuously flowing resin, inside a tailored flow cell. Supported by simulations, the flow profile in the printing area is flattened, and resin velocities at the flow cell walls are increased to minimize unwanted polymerization via laser sheet-induced curing. Various objects are printed continuously and true to shape with smooth surfaces. Parallel object printing paves the way for up-scaling the continuous production, currently reaching production rates up to 1.75 mm3 s-1 for the presented flow cell. Xolography in flow provides a new opportunity for scaling up volumetric 3D printing with the potential to resolve the trade-off between high production rates and high resolution in light-based additive manufacturing.

EfectroH2O: Development and evaluation of a novel treatment technology for high-brine industrial wastewater.

Textile production is one of the main sources of freshwater consumption by industries worldwide. In addition, according to the world bank, 20 % of the wastewater generated globally is caused by textile wet-processing. Textile wet-processing includes the processes in textile production where garments are dyed or given the final functions like water-repellency. Several thousand chemicals were used in this process, some of which are highly toxic. Discharging untreated or insufficiently treated wastewater in water bodies results in high pollution levels, severely impacting the environment and human health. Especially in textile-producing countries like India, environmental pollution and water consumption from textile wet-processing have severe impacts. Next to the high volume of chemicals used in textile production, the high salt concentration in textile wastewater also poses a challenge and is critical for freshwater systems. Moreover, textile wastewater is one of the most difficult to treat wastewater. Currently, used treatment technologies do not meet the requirements to treat textile wastewater. Therefore, the further development of efficient treatment technologies for textile wastewater is critically important. Hence, in the interdisciplinary project, effect-based monitoring demonstrates the efficiency of electrically-driven water treatment processes to remove salts and micropollutants from process water (EfectroH2O), a low-energy Zero Liquid Discharge (ZLD) textile wastewater treatment technology is being developed consisting of a combination of capacitive deionization (CDI) and advanced oxidation processes (AOP). In addition to treatment technology development, methods for evaluating the efficiency of treatment technologies also need to be improved. Currently, mainly physicochemical parameters such as pH, biochemical oxygen demand (BOD) and chemical oxygen demand (COD) are tested worldwide to check water quality. However, these methods are insufficient to make a statement about the toxic potential of such complex mixtures as textile wastewater. Therefore, also next to chemical analyses, effect-based methods (EBM) are used to verify the treated wastewater.

Fabrication, Flow Assembly, and Permeation of Microscopic Any-Shape Particles.

Today, millimeter-sized nonspherical any-shape particles serve as flexible, functional scaffold material in chemical and biochemical reactors tailoring their hydrodynamic properties and active surface-to-volume ratio based on the particle's shape. Decreasing the particle size to smaller than 100 µm would be desired as it increases the surface-to-volume ratio and promotes a particle assembly based on surface interactions, allowing the creation of tailored self-assembling 3D scaffolds. This study demonstrates a continuous high-throughput fabrication of microscopic 3D particles with complex shape and sub-micron resolution using continuous two-photon vertical flow lithography. Evolving from there, in-channel particle fabrication into a confined microfluidic chamber with a resting fluid enables the precise fabrication of a defined number of particles. 3D assemblies with various particle shapes are fabricated and analyzed regarding their permeability and morphology, representing convective accessibility of the assembly's porosity. Differently shaped particles highlight the importance of contact area regarding particle-particle interactions and the respective hydraulic resistance of an assembly. Finally, cell culture experiments show manifold cell-particle interactions promising applicability as bio-hybrid tissue. This study pushes the research boundaries of adaptive, responsive, and permeable 3D scaffolds and granular media by demonstrating a high throughput fabrication solution and a precise hydrodynamic analysis method for micro-particle assemblies.

Particle movements provoke avalanche-like compaction in soft colloid filter cakes.

During soft matter filtration, colloids accumulate in a compressible porous cake layer on top of the membrane surface. The void size between the colloids predominantly defines the cake-specific permeation resistance and the corresponding filtration efficiency. While higher fluxes are beneficial for the process efficiency, they compress the cake and increase permeation resistance. However, it is not fully understood how soft particles behave during cake formation and how their compression influences the overall cake properties. This study visualizes the formation and compression process of soft filter cakes in microfluidic model systems. During cake formation, we analyze single-particle movements inside the filter cake voids and how they interact with the whole filter cake morphology. During cake compression, we visualize reversible and irreversible compression and distinguish the two phenomena. Finally, we confirm the compression phenomena by modeling the soft particle filter cake using a CFD-DEM approach. The results underline the importance of considering the compression history when describing the filter cake morphology and its related properties. Thus, this study links single colloid movements and filter cake compression to the overall cake behavior and narrows the gap between single colloid events and the filtration process.