Fused deposition modelling 3D printing incorporates BiOCl morphology regulation as a strategy for developing bespoke...

Fused deposition modeling (FDM), a widely adopted 3D printing technique, enables fabrication of carrier components for supported photocatalysts, thereby improving recyclability of nanoscale photocatalysts. However, incorporation of a solid carrier requires precise regulation of the reaction system during catalyst preparation to maintain stable and efficient photocatalytic performance. Herein, a maple-leaf-like reactor was fabricated using polylactic acid/poly(butylene adipate-co-terephthalate)/Chlorella composite filaments, followed by surface immobilization of bismuth oxychloride (BiOCl) via a mild, room-temperature solvent-assisted process. Morphology of deposited BiOCl was systematically tuned by adjusting the ethylene glycol-to-ethyl alcohol ratio in solvent system. Photocatalytic performance of as-prepared reactor was comprehensively evaluated using various organic dyes, including rhodamine B (RhB), methylene blue (MB), malachite green (MG), and crystal violet (CV). Results demonstrate that (PML)₅G₁A₂-BOC fabricated at an optimal ethylene glycol-to-ethyl alcohol ratio of 1:2 exhibits superior photocatalytic activity, achieving RhB degradation efficiency of 98.61% within 1 h. Recyclability and durability were investigated through cyclic stability tests, revealing that RhB degradation efficiency remained above 96% after 4 cycles. Photocatalytic degradation mechanism of RhB was further clarified by combining radical trapping experiments with semiconductor band structure analysis, which confirms that photogenerated electrons (e^-) and superoxide radicals (·O^2-) play dominant roles in degradation process. This study provides new insights into FDM-based fabrication of high-performance photocatalysts, offering a customizable and scalable strategy for photocatalytic reactor development and advancing practical applications in environmental pollutant remediation.