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Boost Efficiency while Accelerating Development and Deployment of Cost-Effective Carbon Capture Technologies

3D Printing for Carbon Capture

Recognized as one of the measures needed to mitigate climate change, carbon capture, utilization and storage (CCUS) is seeing increasing investments from large energy companies, tech start-ups and research centres. Developing next generation techniques requires integration of new technologies and key solutions to support:

Improve the Efficiency and Economic Viability of Carbon Capture Technology to Scale Up and Accelerate Decarbonization

  • Carbon capture efficiency

  • Cost-effectiveness improvements

  • Quick transition to full-scale production

Capable of producing designs that couldn’t be done using traditional fabrication methods, 3D Systems’ consultative approach and 3D printing solutions (also called additive manufacturing) can cost-effectively deliver more efficient components, enabling:

  • Increased performance

  • More energy-efficient carbon capture technology

  • Lower carbon footprint with simplified supply chain through distributed manufacturing

The chemical reactions involved in the carbon capture process either require heat or generate heat as a byproduct of the reaction. To control the temperature for ideal reactions, heat exchangers are strategically positioned. Our 3D printing solutions allow to produce more efficient, higher-performance thermal management components.

Heat exchangers

Refinement columns are complex to assemble traditionally while being expensive and requiring very long lead time. Process chambers can include many functional components such as condensors, filters, distillers, chillers, boilers, and heat exchangers, all combined into a stack with thousands of components to be assembled. Components consolidation enabled by 3D printing significantly reduces production lead times, streamlines supply chain and addresses energy-efficiency requirement.

Gas condensers

Turbomachinery improves efficiency in flue gas diversion and distributed carbon capture applications, increasing the amount of gas driven into the system. Our 3D printing solutions minimize turbomachinery downtime, improve supply chain efficiency, and lower costs with optimally designed components.

Turbine components

True design iteration and practical tests to find the ideal design solution faster is crucial. Our 3D printing solutions offer rapid prototyping capabilities, so you validate and get to the final, optimum design faster.

Speed of Iteration

Dramatically boost carbon capture systems’ performance and efficiency leveraging the design optimization capability of 3D printing. Peak efficiency means there is no energy loss in system operation which translates to a lower cost per ton.

Design Optimization

Metal 3D printed components are made for reliability and extensive service life. 3D print using a range of alloys that are high temperature and corrosion-resistant while possessing high thermal conductivity.

Long Service Life

The Benefits of 3D Printing to Accelerate Carbon Capture

Partner with us to develop new concepts and solutions, and quickly scale to production volumes. We provide full support to address our customers' challenges and help establish your own additive manufacturing capabilities.

Expert Consultancy

Not only accelerating the development of cost-effective and energy-efficient new technologies, these innovative solutions also become rapidly available via scalable additive manufacturing to support the massive need in the field for equipment.


Part consolidation and monolithic design capabilities enable quality and streamlining of the supply chain. Eliminate the carbon footprint of using multiple suppliers across the country to produce a single assembly.

Supply Chain Efficiencies

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Create filter structures maximizing contact between incoming air and the filter surface for more efficient carbon “capture”. Optimally design for high levels of turbulence and mixing, as well as high surface area for maximum air contact. 

Gas contactors

The Role of 3D Printing in Carbon Capture Technology

Removing carbon from the atmosphere requires a system of filters, heat exchangers, condensers, gas separators, and compressors. To increase direct air capture (DAC) performance and economic benefits, many of these complex components involve geometries that are well-suited to 3D printing. Our 3D printing solutions address prototyping and production needs for a vast array of these carbon capture technology key components. Examples include:

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