How ValCUN’s 3D Printed Catalytic Air Purification Systems Reduce Costs by 37%

In a world increasingly concerned with air quality and sustainable industrial processes, 3D printed catalytic air purification systems are revolutionising the way emissions are treated. ValCUN has partnered with AddCat, a Dutch air purification innovator, to create next-generation catalytic reactors using aluminium and additive manufacturing. The result? A cleaner, more cost-efficient solution that redefines industry standards.

The Air Purification Challenge

Catalytic air purification systems are crucial in reducing harmful emissions from industrial and agricultural processes. However, the market—valued at €300 million—is constrained by two major challenges:

• High material costs, especially for rare metals like palladium.
• Limited design freedom, which restricts performance optimisation.

Traditional manufacturing methods limit the reactor geometry and make it difficult to reduce catalytic material use without sacrificing performance. While metal 3D printing has introduced some flexibility, technologies like LPBF or binder jetting remain expensive and material-limited.

Why 3D-Printed Catalytic Air Purification Systems Matter

This is where 3D printed air purification systems with aluminium come into play. ValCUN’s proprietary Molten Metal Deposition (MMD) technology enables complex geometries to be printed affordably and at scale. These shapes would be impossible or cost-prohibitive with conventional techniques.

The use of aluminium, with its high thermal conductivity, dramatically enhances the conversion rate of pollutants at lower operating temperatures. As a result, the reactor performs more efficiently and consumes less catalytic material.

ValCUN’s Innovative Solution

ValCUN’s MMD technology allows:

• Support-free printing, which speeds up production.
• Raster-like surface finishes, optimising catalytic coating adhesion.
• Aluminium-based substrates, reducing weight and enhancing heat transfer.

A critical benefit of this technology is its recyclability. After a 10-year reactor lifespan, the catalytic materials can be recovered, unlike traditional systems that typically degrade after just 3 years. This feature enables up to 30% CAPEX recovery—a massive leap in sustainability and cost-effectiveness.

Measurable Results

When tested against a conventional reactor and AddCat’s original design, ValCUN’s additively manufactured catalytic air purification systems achieved outstanding results:

• Higher conversion efficiency, thanks to aluminium’s thermal properties.
• Substrate manufacturing costs reduced by 4x.
• Total cost of ownership lowered by 37% per year per volume converter.

These results prove that aluminum catalytic air purification systems are not just a theoretical innovation—they’re a commercially viable, environmentally sound alternative.

Towards a Cleaner, More Efficient Future

By integrating 3D-printed catalytic air purification systems into emission control strategies, companies can achieve better performance at a lower cost, while making strides toward circularity and sustainability.

ValCUN is proud to enable this transition with our MMD technology—delivering the future of air purification, one layer at a time.