Integrating Metal–Organic Frameworks and Polyamide 12 for Advanced Hydrogen Storage Through Powder Bed Fusion

This paper introduces a pioneering approach that combines ex situ synthesis with advanced manufacturing to develop ZIF-67-PA12 Nylon composites with mixed-matrix membranes (MMMs), with the goal of enhancing hydrogen storage systems. One method involves producing MOF-PA12 composite powders through an in situ process, which is then commonly used as a base powder for powder bed fusion (PBF) to fabricate various structures. However, developing the in situ MOF-PA12 matrix presents challenges, including limited spreadability and processability at higher MOF contents, as well as reduced porosity due to pore blockage by polymers, ultimately diminishing hydrogen storage capacity. To overcome these issues, PBF is employed to form PA12 powder into films, followed by the ex situ direct synthesis of ZIF-67 onto these substrates at loadings exceeding those typically used in conventional MMM composites. In this study, ZIF-67 mass loadings ranging from 2 to 30 wt.% were synthesized on both PA12 powder and printed film substrates, with loadings on printed PA12 films extended up to 60 wt.%. ZIF-67-PA12-60(f) demonstrated a hydrogen capacity of 0.56 wt.% and achieved 1.53 wt.% for ZIF-67-PA12-30(p); in comparison, PA12 exhibited a capacity of 0.38 wt.%. This was undertaken to explore a range of ZIF-67 Metal–organic frameworks (MOFs) to assess their impact on the properties of the composite, particularly for hydrogen storage applications. Our results demonstrate that ex situ-synthesized ZIF-67-PA12 composite MMMs, which can be used as a final product for direct application and do not require the use of in situ pre-synthesized powder for the PBF process, not only retain significant hydrogen storage capacities, but also offer advantages in terms of repeatability, cost-efficiency, and ease of production. These findings highlight the potential of this innovative composite material as a practical and efficient solution for hydrogen storage, paving the way for advancements in energy storage technologies.