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Novel monolithic catalyst supports with regular three-dimensional structure and channel-to-channel interconnectivity have been fabricated using a direct ceramic fabrication technique known as robocasting. Using the oxidation of CO over a Pt/γ-Al 2 O 3 catalyst as a probe reaction, we have quantified the mass transfer over several new geometries and compared them to traditional straight-channel monolithic supports. A geometry of alternating rods that presents no line-of-sight flow paths and about 45% void volume increases the dimensionless Sherwood number by a factor of 3 over that of traditional honeycomb supports. However, the resulting pressure drop is similar to that of a packed bed (up to a 1000-fold increase). A similar robocast structure with 74% void volume improves the Sherwood number by a factor of about 1.5 relative to the honeycomb geometry but only increases the pressure drop by a factor of 4. The results illustrate that robocasting technology affords an unprecedented degree of freedom, allowing optimization of ceramic monoliths for specific applications.

Monolithic Supports with Unique Geometries and Enhanced Mass Transfer