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Mineral precipitation reactions in porous media can change the porosity and permeability of the rock formations. Predicting the rate of reaction and impacts on formation properties is challenging due to a lack of understanding of mineral precipitation reaction kinetics and mechanisms in porous media. This is furthermore challenging due to the highly heterogeneous nature of natural porous media. Here, we aim to develop a novel experimental platform leveraging 3D printing to facilitate replicable mineral precipitation experiments in controlled, heterogenous porous media systems. This requires fundamental understanding of the kinetics of mineral precipitation on the polymer materials used to fabricate the 3D printed porous media. In this work, we manipulate (via sulfonation) material surfaces (high impact polystyrene, HIPS) to promote calcite precipitation from supersaturated solutions to inform the design of synthetic subsurface systems. Calcite precipitation on HIPS films of varied surface sulfonation is confirmed using X-ray diffraction (XRD) analysis and weight-based precipitation experiments where increased precipitation with increased surface functionalization and solution saturation index are observed. This approach is then applied to 3D-printed porous media to enhance understanding of geochemical reactions, specifically calcite precipitation. Three dimensional images of Bentheimer Sandstone are used as the basis for 3D-printed porous media samples. Two 3D-printed samples were functionalized with acid to activate the surface and promote mineral precipitation. Functionalized and unfunctionalized samples underwent calcite precipitation core flooding experiments with oversaturated calcite solutions for 96 hours. Three dimensional X-ray micro-CT imaging revealed calcite growth in functionalized samples, with a calcite volume fraction of approximately 2.6% and a substantial reduction in porosity. Unfunctionalized samples exhibited diminished calcite precipitation and porosity changes. These findings demonstrate that reactive 3D-printed porous media can provide a versatile geochemical modeling and experimentation platform. Functionalizing 3D printed samples enhances reactivity, allowing investigations of mineral precipitation processes in complex porous media. This research highlights the potential for further exploration of 3D-printed media in various geochemical contexts. 

Polymer composites are becoming an important class of materials for a diversified range of industrial applications due to their unique characteristics and natural and synthetic reinforcements. Traditional methods of polymer composite fabrication require machining, manual labor, and increased costs. Therefore, 3D printing technologies have come to the forefront of scientific, industrial, and public attention for customized manufacturing of composite parts having a high degree of control over design, processing parameters, and time. However, poor interfacial adhesion between 3D printed layers can lead to material failure, and therefore, researchers are trying to improve material functionality and extend material lifetime with the addition of reinforcements and self-healing capability. This review provides insights on different materials used for 3D printing of polymer composites to enhance mechanical properties and improve service life of polymer materials. Moreover, 3D printing of flexible energy-storage devices (FESD), including batteries, supercapacitors, and soft robotics using soft materials (polymers), is discussed as well as the application of 3D printing as a platform for bioengineering and earth science applications by using a variety of polymer materials, all of which have great potential for improving future conditions for humanity and planet Earth.