Enhanced catalytic combustion of methane gas was achieved using novel ceramic support structures. These support structures consist of a three-dimensional lattice of rods, created by a direct fabrication technique (robocasting). The rods (725-1000 µm in diameter) are oriented in such a way as to create no line-of-sight pathways, to have high surface-to-volume ratios (15-43 cm 2 /cm 3 ), and to generate highly turbulent flow, promoting increased mass transfer without sacrificing low pressure drops when compared to conventional extruded-honeycomb supports. The flow behaviors of both robocast and honeycomb supports were characterized, and the catalytic activities for the combustion of methane gas were compared. Under otherwise equivalent conditions, robocast lattices converted approximately 6 times more methane at 600 °C than extruded-honeycomb supports.
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