Fabrication of a stacked Archimedean spiral reactor with porous carbon walls using 3D-printed PLA as internal sacrificial template and carbonized whey powder as porous carbon matrix

This study introduces a method to create porous carbon structures with intricate internal voids. 3D-printed PLA acts as an internal sacrificial template, combined with carbonized whey powder as the porous carbon matrix. Sintering whey powder at 150°C yields solid pieces that, upon carbonization, result in highly porous carbon objects while maintaining the original mold shape. Temperature control ensures successful whey powder sintering before PLA melting. The use of PLA sacrificial templates, along with whey carbonization, allows for developing devices with finely tailored internal voids, as demonstrated through a double Archimedean spiral reactor with porous carbon walls.