This research details the use of direct three-dimensional
(3D)
printing technology to create membranes with integrated square-shaped
porous feed spacers made of poly(ether sulfone) (PES). Various concentrations
of PES (18, 20, 22, 25, and 28 wt %) in the 3D printing solution were
employed to evaluate the impact of solution viscosity on 3D-printed
spacer fidelity and membrane performance. Comparative analysis with
the FS18 membrane, which utilizes a plastic polylactic acid (PLA)
feed spacer and flat PES membrane, revealed a substantial improvement
in pure water flux (31.0–130%) for the integrated membranes,
mainly attributed to the augmented effective surface area (2.41–39.7%)
created by the porous PES feed spacer patterns. However, this enhancement
is viscosity-dependent, as evidenced by the reduced spacer pattern
fidelity in the P18 (18 wt % PES) membrane with low-viscosity 3D printing
solution, leading to diminished overall membrane effectiveness. Remarkably,
when compared to the flat membrane, the integrated membranes (except
P18 membrane) demonstrated better antifouling behavior, regardless
of whether a plastic PLA feed spacer was used or not. This is attributed
to elevated shear stresses on the porous spacer pattern peaks and
induced turbulence, acting as a protective shield against severe membrane
fouling. Overall, this study highlights the effectiveness of direct
3D printing in seamlessly integrating porous PES feed spacers onto
membrane surfaces, offering potential for optimization and exploration
of diverse polymers in the 3D printing process.