This study introduces a novel solution to the design of structured catalysts, integrating single‐piece 3D printing with single‐atom catalysis. Structured catalysts are widely employed in industrial processes, as they provide optimal mass and heat transfer, leading to a more efficient use of catalytic materials. They are conventionally prepared using ceramic or metallic bodies, which are then washcoated and impregnated with catalytically active layers. However, this approach may lead to adhesion issues of the latter. By employing photopolymerization printing, a stable and active single‐atom catalyst is directly shaped into a stand‐alone, single‐piece structured material. The battery of characterization methods employed in the present study confirms the uniform distribution of catalytically active species and the structural integrity of the material. Computational fluid dynamics simulations are applied to demonstrate enhanced momentum transfer and light distribution within the structured body. The materials are finally evaluated in the continuous‐flow photocatalytic oxidation of benzyl alcohol to benzaldehyde, a relevant reaction to prepare biomass‐derived building blocks. The innovative approach reported herein to manufacture a structured single‐atom catalyst circumvents the complexities of traditional synthetic methods, offering scalability and efficiency improvements, and highlights the transformative role of 3D printing in catalysis engineering to revolutionize catalysts’ design.

中文翻译：

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通过高分辨率光聚合 3D 打印制造结构化单原子催化剂

这项研究引入了一种新颖的结构催化剂设计解决方案，将单件 3D 打印与单原子催化相结合。结构化催化剂广泛应用于工业过程中，因为它们提供最佳的传质和传热，从而更有效地利用催化材料。它们通常使用陶瓷或金属体制备，然后用催化活性层进行修补和浸渍。然而，这种方法可能会导致后者的粘附问题。通过采用光聚合印刷，稳定且活性的单原子催化剂被直接成型为独立的单片结构材料。本研究中采用的一系列表征方法证实了催化活性物质的均匀分布和材料的结构完整性。应用计算流体动力学模拟来证明结构体内增强的动量传递和光分布。这些材料最终在苯甲醇到苯甲醛的连续流光催化氧化中进行评估，这是制备生物质衍生构建块的相关反应。本文报道的制造结构化单原子催化剂的创新方法规避了传统合成方法的复杂性，提供了可扩展性和效率改进，并强调了 3D 打印在催化工程中彻底改变催化剂设计的变革性作用。