# Innovative 3D-Printed Superhydrophobic Porous Architectures for Continuous Oil–Water Separation

## TL;DR

This paper presents a new 3D-printing method to create superhydrophobic materials that efficiently separate oil and water for environmental and industrial use.

## Contribution

The study introduces the smallest reported fused filament fabrication pore size and a scalable method for continuous oil–water separation.

## Key findings

- 3D-printed structures with pore sizes as small as 186.7 µm were successfully fabricated.
- The superhydrophobic material achieved a water contact angle of 158.2° and maintained 88.6% separation efficiency for 24 hours.
- The method offers a low-cost, durable solution for oil spill cleanup and wastewater treatment.

## Abstract

Efficient superhydrophobic oil–water separation materials are essential for environmental remediation and industrial wastewater treatment. In this study, by optimizing printing parameters, such as printing speed, extrusion multiplier, and layer height, we achieved high-precision 3D porous architectures with uniform pore sizes. The pore size could reach 677.3 µm, with a maximum deviation of less than 36.1 µm. Additionally, we successfully printed pores as small as 186.7 µm, representing the smallest FFF-printed pore size reported in the literature. The printed structures were modified using a spray-coating method, achieving a superhydrophobic surface with a water contact angle of 158.2°. The material was tested in a continuous oil–water separation system, maintaining stable oil removal performance for 24 h. The highest separation efficiency reached 88.6%, demonstrating strong durability and long-term applicability. This study establishes a scalable, low-cost approach for fabricating highly efficient 3D superhydrophobic porous materials, offering new opportunities for continuous oil spill cleanup and industrial wastewater treatment.