Enhanced Mechanical Properties of Direct Ink Writing (3D Printed) Hexagonal Boron Nitride Reinforced Porous Boehmite Structures

3D printing techniques offer a unique opportunity to build unconventional shapes to enhance operational performance. Boehmite structures that are 3D printed using direct ink writing (DIW) technique are employed as catalytic carriers; however, their inadequate fracture resistance poses a drawback. Therefore, this study aims to improve the mechanical properties of 3D-printed boehmite structures by reinforcing hexagonal boron nitride (hBN) nanosheets. Herein, the DIW of boehmite structures is reported where porosity and surface area relevant for industrial applications have been achieved. Since porosity enhancement is a trade-off with mechanical strength, reinforcement of 3D printing boehmite ink is done with hBN in an effort to increase its fracture strength without compromising porosity. There are varied hBN concentrations in the composite to study its impact on the mechanical strength of 3D-printed cylindrical structures tested under compression techniques. The as-developed composite structure with 1% hBN reinforcement has excellent printability and better mechanical strength (19% compression strength enhancement compared to pure boehmite) without compromising functional properties such as thermal stability and surface area. For catalytic carriers, porosity enhancement is a trade-off with mechanical strength; therefore, hBN-reinforced boehmite composite structure is developed via direct ink writing technique. The as-developed composite structure has excellent printability and better mechanical strength without compromising functional properties such as thermal stability and surface area.image (c) 2024 WILEY-VCH GmbH