Monoliths for gas storage manufactured with precision pore engineering using 3D-printed templates

•Produced activated carbon monoliths (ACMs) with transport porosities of up to 9%.•Monoliths have customizable transport pore structure at 3D printer resolution scale.•Sequential pyrolysis allows independent control of porosity and properties of ACMs.•The production method can be extended to other materials and aid other processes. A fast, customizable, and systematic route for producing activated carbon monoliths for gas storage with low interparticle porosity (9 % to 24 %) containing tailored macro channels is disclosed. The production uses a three-dimensional (3D)-printed polymeric lattice, rich in oxygen, as a sacrificial template. Its interstitial voids are filled with a phenolic resin that is carbonized and activated at 1173 K under carbon dioxide (CO2). Sequential pyrolysis occurs via thermal treatment with the 3D-printed lattice removed first, rendering macro channels with the same shape as the template in accurately placed positions. Resulting in adsorbents with interparticle porosities ranging from 10 % to 23 %, calculated from X-ray micro-computed tomography (micro-CT) images. The axial resolution of these macro channels was similar to the SLA printing layer thickness used of 100 µm. Making it the best resolution attained to date in fabricating monoliths via a 3D-printed sacrificial templating method. Breakthrough experiments indicated healthy macro channel connectivity due to the reduced mass transfer zone. Moreover, excellent mechanical integrity was displayed, with a monolith withstanding 900 N before excessive fracturing occurred despite the presence of macro channels. Therefore, this method emphasizes its use for gas storage applications by enabling the adsorbent material to efficiently utilize the volumetric space while allowing a fast rate of adsorption over the entire structure.