Abstract:
Geopolymers are emerging as sustainable alternatives to Portland cement due to their low-carbon footprint, durability, and versatility. Recent advances in additive manufacturing have enabled the production of complex structures, yet the fabrication of macroporous geopolymers suitable for environmental applications remains largely unexplored. Creating stable, visibly macroporous structures could significantly enhance their utility in water treatment, thermal insulation, and sustainable infrastructure. The objective of this study was to optimize 3D-printable geopolymer-based formulations capable of producing interconnected macroporous networks with high structural integrity and chemical durability. Metakaolin (Tempozz M88) was used as the alumino-silicate precursor and activated with potassium silicate solution (Geosil 14517, SiO?/K?O = 1.7). Rheological studies including viscosity, shear stress, and oscillatory responses were conducted to tailor printability. Fillers such as feldspar and wollastonite were incorporated to improve mechanical strength and reduce shrinkage, while xanthan gum
acted as a gelling agent. Porosity-inducing modifiers were introduced at the final stage. Printing was performed under controlled air pressure (1.5-4.5 bar) using a 1 cm nozzle to achieve consistent extrusion and precise layer stacking. The optimized formulations yielded 3D-printed samples with well-connected macroporous networks clearly visible to the naked eye. Despite their high porosity, the structures maintained sufficient compressive strength and exhibited excellent resistance to aggressive acidic environments. Preliminary adsorption tests confirmed the effectiveness of these materials for contaminant removal from water. This first demonstration of 3D-printed macroporous geopolymers highlights their feasibility for advanced environmental applications. Their unique advantages include chemical stability, high mechanical and thermal resistance, low-cost and sustainable raw materials, compatibility with 3D printing, and potential for hybrid multifunctional platforms, promising candidates for scalable solutions in filtration, adsorption, insulation, and eco-friendly infrastructure.
Biography:
Youssef Ettahiri is a researcher specialized in the physico-chemistry of materials, with interdisciplinary expertise in the development and characterization of advanced geopolymer-based materials. His work covers a wide range of geopolymer systems, including porous, photocatalytic, and acid-resistant materials, as well as geopolymer concrete and additive manufacturing (3D printing) of geopolymer structures. Motivated by the pursuit of durable and high-performance materials, his research addresses applications such as CO₂ capture, pollutant adsorption, photocatalysis, thermal insulation, and infrastructure durability. By combining experimental research with materials engineering, he aims to contribute to the development of eco-efficient technologies serving both the environment and industry.
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