3D-Printed 1000°C Silicon-Carbide Thermocatalytic CO2 Reactor with High Carbon Conversion and Energy Efficiencies

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OPEN 2021
Ithaca, New York
Project Term:
05/16/2022 - 06/01/2025

Technology Description:

Dimensional Energy will apply additive manufacturing (AM) of large-scale ceramics to 3D print a reactor that will efficiently convert greater than 70% of CO2 and green H2 into synthetic gas (syngas), which may be used to produce synthetic aviation fuel. The high carbon utilization and energy efficiencies of the reactor will be coupled with inexpensive renewable electricity and green electrolysis-produced H2 to enable syngas production. Further processing will yield sustainable aviation fuel and other sustainable fuels and chemicals. The ultra-high temperature reactor will include structural features and architectures to achieve higher energy efficiency, compactness, temperature uniformity, and ease of system integration.

Potential Impact:

Dimensional Energy’s innovative reactors will convert CO2 into a feedstock chemical that can be processed into jet fuel, thereby providing a low-carbon and sustainable aviation fuel to an air flight sector that accounts for nearly 3% of global annual emissions.


The team’s processes will enable scalable production and assembly of 3D printed components into leak-free reactors with high thermal stability.


This prototype reactor will be coupled to inexpensive renewable electricity and green H2 to enable production of syngas for sustainable aviation fuel from captured CO2.


This project will utilize CO2 to create sustainable aviation fuel below $2/gal.


ARPA-E Program Director:
Dr. James Seaba
Project Contact:
Dr. Bradley Brennan
Press and General Inquiries Email:
Project Contact Email:


Oak Ridge National Laboratory

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