Optimizing Surface Area of Structured Packing via Advanced 3D Printing Techniques

This study focuses on the production of single rectangular sheets, representing the repetitive unit of a structured packing but simplified to a flat geometry without holes or corrugations and explores the use of 3D foam-printing to improve their texture and enhance their surface area and wettability properties for packed column applications. Two types of surface textures (wavy and pyramid patterns) inspired by industrial designs are produced: one set with conventional Polylactic Acid (PLA) filaments and another using CO2-foamed PLA filaments. The printing and foaming parameters are optimized to maximize the surface area of the textures. Surface properties are analyzed using Scanning Electron Microscopy (SEM) for micro-roughness and confocal microscopy for the full range of roughness. Results show a 5–23% increase in surface area, supporting a more efficient mass transfer. This approach presents a promising pathway for developing advanced, high-performance surfaces for process intensification in packed column applications.