PRINTCR3DIT · Project

3D-Printed Chemical Reactors That Cut Energy Use and Boost Production Efficiency

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Imagine you could 3D-print the inside of a chemical reactor the same way you'd print a custom phone case — but instead of plastic, you're shaping catalytic surfaces that speed up chemical reactions. Traditional reactors are like one-size-fits-all cooking pots: they work, but they waste heat and don't mix ingredients efficiently. This project designed and built 3D-printed reactors and catalysts tailored to specific reactions, from fine chemicals to fertilizers, squeezing more product out of less energy. They even built a working demonstrator unit producing squalane, a high-value ingredient used in cosmetics and lubricants.

By the numbers

90%

Share of chemicals produced using catalytic reactors

<15%

Energy consumption reduction target

Consortium partners

Countries represented

SMEs in the consortium

EUR 5,493,889

EU contribution to the project

Market segments demonstrated (fine chemicals, specialty chemicals, fertilizers)

The business problem

What needed solving

Chemical manufacturers waste significant energy and raw materials because conventional reactors use generic, one-size-fits-all designs that create bottlenecks in heat transfer, mixing, and flow distribution. Catalytic reactors produce 90% of everyday chemicals, yet traditional manufacturing methods cannot create the complex internal geometries needed to optimize each specific reaction. Companies face a choice between expensive custom engineering or accepting suboptimal performance.

The solution

What was built

The project built catalytic SiC foam supports with deposited catalytic phases on 3D-printed structures, a manufactured 3D-printed reactor for the demonstrator unit, and a complete physical demonstrator for squalane production. These covered three market segments: fine chemicals, specialty chemicals, and fertilizers.

Audience

Who needs this

Specialty and fine chemical manufacturers with heat transfer or mixing bottlenecksFertilizer producers seeking to reduce energy costs at scaleCosmetics ingredient companies producing squalane or similar high-value compoundsChemical engineering firms designing custom reactor solutions for clientsIndustrial catalyst suppliers looking to offer 3D-printed structured catalysts

Business applications

Who can put this to work

Chemical Manufacturing

enterprise

Target: Mid-to-large chemical producers making specialty or fine chemicals

If you are a specialty chemicals manufacturer dealing with poor heat transfer and mixing in your reactors — this project developed 3D-printed catalytic reactor internals that can be custom-shaped to your specific reaction. The demonstrator showed production of squalane using these tailored reactors. With 14 partners across 7 countries validating the approach, this is proven technology ready for industrial conversation.

Fertilizer Production

enterprise

Target: Fertilizer plants looking to reduce energy consumption and increase throughput

If you are a fertilizer producer spending heavily on energy for large-scale catalytic processes — this project demonstrated that 3D-printed reactor designs can reduce energy consumed by up to 15%. The technology was tested across markets ranging from few tons to millions of tons per year, directly relevant to fertilizer-scale operations. Retrofitting existing plants is explicitly part of the business case developed.

Cosmetics & Personal Care

mid-size

Target: Companies producing squalane or other high-value bio-based ingredients

If you are a cosmetics ingredient supplier struggling with costly batch production of squalane — this project built and delivered a working demonstrator unit specifically for squalane production using 3D-printed catalytic reactors. The technology enables continuous-flow processing with better thermal management, potentially replacing inefficient batch setups. The consortium included 6 SMEs experienced in scaling such solutions.

Frequently asked

Quick answers

What would it cost to adopt 3D-printed reactor technology in my plant?

The project did not publish per-unit costs. However, with EUR 5,493,889 in EU funding and 14 partners involved, the R&D investment was substantial. The project explicitly developed business case scenarios for both new integrated plants and retrofitting, suggesting cost models exist — contact the consortium for specifics.

Can this scale to industrial production volumes?

Yes — the project was specifically designed to cover markets from few tons to millions of tons of production per year, including fertilizers at the high end. The demonstrator unit for squalane production was a physical delivery proving the concept at meaningful scale. The methodology was built to be generic and systematic for implementation across different scales.

Who owns the IP and can I license this technology?

The project involved 14 partners including 4 world-leading industries and 4 innovative SMEs. IP is likely shared among consortium members under standard Horizon 2020 rules. Licensing arrangements would need to be discussed directly with SINTEF AS (coordinator) or the relevant technology-developing partners.

How much energy can this actually save?

The project objective states energy consumption reduction of less than 15% compared to conventional reactor designs. This figure comes from improved heat transfer, mixing, and flow distribution enabled by 3D-printed geometries that are impossible to manufacture with traditional tools.

Is this compatible with my existing production line?

The project explicitly considered retrofitting as a deployment path alongside new integrated plants. The 3D-printed components — catalytic supports and reactor internals — are designed to be adaptable to existing reactor shells. Business case scenarios for retrofitting large-scale applications were part of the project deliverables.

What specific products were demonstrated?

The project delivered three key physical outputs: catalytic SiC foam supports with deposited catalytic phase, a 3D-printed reactor for the demonstrator unit, and a complete demonstrator for squalane production. Squalane is a high-value chemical used in cosmetics and lubricants, and a monomer-based product was also targeted.

Consortium

Who built it

The PRINTCR3DIT consortium is heavily industry-oriented: 8 out of 14 partners (57%) are from industry, including 6 SMEs, alongside 5 research institutes and 1 university. This balance signals real commercial intent — the project wasn't just an academic exercise. Led by SINTEF AS, one of Europe's largest independent research organizations based in Norway, the consortium spans 7 countries (CZ, DE, ES, FR, NO, PT, UK), covering major European chemical manufacturing hubs. The presence of 4 world-leading industrial companies alongside 4 innovative SMEs suggests both market access and agility for technology transfer. For a business buyer, this means multiple potential technology suppliers and licensing partners already exist within the consortium.

SINTEF ASCoordinator · NO
USTAV CHEMICKYCH PROCESU AV CR, v. v. i.participant · CZ
STIFTELSEN SINTEFparticipant · NO
FUNDACION IDONIALparticipant · ES
LINDE GMBHparticipant · DE
ARKEMA FRANCE SAparticipant · FR
UNIVERSIDADE DO PORTOparticipant · PT
Yara International ASAparticipant · NO
CENTRE TECHNOLOGIQUE NOUVELLE-AQUITAINE COMPOSITES & MATERIAUX AVANCESparticipant · FR
JOHNSON MATTHEY PLCparticipant · UK

How to reach the team

SINTEF AS is the coordinator — a major Norwegian research organization. SciTransfer can facilitate a direct introduction to the right team.

Order a report on this consortium See SINTEF AS profile →

Next steps

Talk to the team behind this work.

Want to explore whether 3D-printed reactor technology fits your production process? SciTransfer can arrange a confidential briefing with the PRINTCR3DIT team and assess fit for your specific application.

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