Fabrication of microfiltration-inspired layered microfilter structures using additive manufacturing for water treatment

The fabrication of conventional microfiltration membranes often faces challenges of limited customization, scalability, and high production cost. Additive manufacturing, particularly vat photopolymerization, offers precise control over complex geometries and layered pore structures. In this study, microfiltration-inspired polymeric microfilter structures with layered pores were fabricated using stereolithography (SLA)–based vat photopolymerization. The effects of design type, layer height, and rod diameter on dimensional accuracy, build time, and flow performance were evaluated using a Taguchi L18 experimental design and analysis of variance. The printed membranes achieved high dimensional accuracy (98–99 %), rapid build times (5–9 min), and estimated permeation fluxes of 120–360 L m⁻² h⁻¹ bar⁻¹ under gravity-driven flow. Statistical analysis revealed that layer height and rod diameter were the dominant factors influencing both fabrication fidelity and filtration clarity, while design variation had minimal effect. These findings demonstrate the feasibility of SLA 3D printing for the rapid and customizable fabrication of architected microfilter structures inspired by microfiltration membrane concepts, establishing a proof-of-concept foundation for future development of hybrid, coated, or composite membrane systems for water treatment applications.