Compared to single-scale porous structures, multi-scale porous materials are distinguished by their unique hierarchical architecture composed of macro-, meso-, and micro-pores. These materials are widely adapted in nature and endowed with high surface area, improved transport efficiency, and reduced weight due to their structural design. Such characteristics lead to various applications, especially in filtration and adsorption. In this study, a dual-templating method integrating freeze casting and 3D-printing sacrificial templating techniques was employed to develop multi-scale porous scaffolds with pore sizes distributed across three distinct length scales. Gyroid, a type of triply periodic minimal surface (TPMS) structure, was selected for the millimeter-scale channel design because of their high permeability, non-tortuous fluid pathways, and interconnected pores. Moreover, periodic gyroid structures can be described by mathematical equations, allowing for the systematic designs of 3D models. By varying the volume fractions of the 3D-printed gyroid templates and the cooling rates during the freeze casting process, pore sizes at both millimeter and micrometer scales can be tuned to achieve desired structures. Furthermore, the smallest pores were provided by diatomites, the fossilized silica-based algae with inherent nanoscale pores, offering extremely high surface area and porosity. Permeability experiments were conducted to further explore the influence of multi-scale pores on fluid transportation properties. Results showed that scaffolds with three scales of pore sizes (millimeter, micrometer, and nanometer) exhibited up to 58 times increase in permeability compared to those with two scales of pore sizes (micrometer and nanometer). Additionally, by leveraging the inherent functional groups on diatomites, multi-scale porous scaffolds were used in methylene blue dye adsorption experiments, revealing a dye removal efficiency of 63%. In conclusion, this study integrated freeze casting and additive manufacturing methods for multi-scale porous ceramics with tunable structural features and functionalities, which can be applied in wastewater treatment, ultra-lightweight structural materials and other engineering fields.
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