ASU Discovers New Ways to Print Porous Structures

Arizona State University researchers have developed a method to 3D print microscale, nanoporous copper structures that expand the capabilities of metal additive manufacturing. Led by Assistant Professor Xiangfan Chen and Associate Professor Bruno Azeredo in the School of Manufacturing Systems and Networks, the team combined high-resolution micro continuous liquid interface production (µCLIP) with engineered nanoporous copper powders to lower sintering temperatures and accelerate printing.

Supported by NSF grants, their work produced centimeter-scale lattice architectures with nanoscale pores, enabling modification of material properties via post-sintering temperature: higher temperatures yield dense, conductive copper; lower temperatures preserve nanoporous structure with high surface area and chemical reactivity.

An unexpected discovery—rapid oxidation and disintegration of porous copper when exposed to air after sintering—was reframed as a feature rather than a flaw. The team envisions applications in information security (self‑destructing components that protect sensitive data), energy, medical devices (transient implants), and other systems needing controlled reactivity or lightweight, high-performance materials. Published in Nature Communications, the research demonstrates how architectural control across scales lets engineers “program” material behavior—balancing durability and intentional transience—and opens new directions for responsive, energy-efficient, and application-specific metallic components.