# DoE-Based Optimization of a Photocatalytic C‑Alkylation Reaction in a 3D-Printed Photoreactor

## TL;DR

This paper introduces a 3D-printed photoreactor and a DoE-based method to optimize a photocatalytic reaction, achieving higher yields and improved sustainability.

## Contribution

A 3D-printed photoreactor and DoE-based optimization method for scalable, sustainable photocatalytic reactions.

## Key findings

- A 48% yield improvement was achieved using a 24 full factorial DoE approach.
- A modified energy economy factor showed increased energy efficiency for the process.
- The optimized reaction was successfully implemented in continuous flow synthesis.

## Abstract

Photocatalysis provides
a sustainable approach to chemical synthesis
by enabling energy-efficient transformations under mild conditions.
In this study, we present a comprehensive method that combines the
development of photocatalytic reactions with process optimization,
using a standardized 3D-printed photoreactor platform. We utilized
the organophotocatalyst 4CzIPN to systematically optimize the visible-light-mediated
carbon–carbon bond formation between the CH-acidic methyl cyanoacetate
and 1,1-diphenylethylene. This optimization was performed through
a 24 full factorial design of experiments (DoE) resulting
in a 48% improvement in yield (up to 91%). To address the persistent
challenge of reproducibility in photochemical research, we employed
a custom-designed, 3D-printed, open-access photoreactor. This design
allows for standardized conditions and enhanced process optimization.
We conducted a systematic investigation of various reaction parameters,
including the conditions and the substrate scope. To assess the sustainability
of the process, we introduced a modified energy economy factor specifically
tailored for photoreactions, which illustrates a significant increase
in energy efficiency. Finally, we demonstrate the possible implementation
of the optimized reaction in continuous flow synthesis, underscoring
the practical applicability of this methodology for advancing the
design of scalable and sustainable photochemical manufacturing.