Transforming CO2 into advanced 3D printed carbon nanocomposites

The conversion of CO2 emissions into valuable 3D printed carbon-based materials offers a transformative strategy for climate mitigation and resource utilization. Here, we 3D print carbon nanocomposites from CO2 using an integrated system that electrochemically converts CO2 into CO, followed by a thermocatalytic process that synthesizes carbon nanotubes (CNTs) which are then 3D printed into high-density carbon nanocomposites. A 200 cm2 electrolyzer stack is integrated with a thermochemical reactor for more than 45 h of operation, cumulatively synthesizing 37 grams of CNTs from CO2. A techno-economic analysis indicates a 90% cost reduction in CNT production on an industrial scale compared to current benchmarks, underscoring the commercial viability of the system. A 3D printing process is developed that achieves a high nanocomposite CNT concentration (38 wt%) while enhancing composite structural attributes via CNT alignment. With the rapidly rising demand for carbon nanocomposites, this CO2-to-nanocomposite process can make a substantial impact on global carbon emission reduction efforts. This work develops a method to sequester carbon emissions into valuable 3D printed materials. By combining a reactor cascade with advanced additive manufacturing, this system offers the ability for carbon utilization at scale, a crucial step for addressing climate change.