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oai:keep.lib.asu.edu:node-2013992025-06-09T23:58:12Zoai_pmh:alloai_pmh:repo_items

201399 https://hdl.handle.net/2286/R.2.N.201399 http://rightsstatements.org/vocab/InC/1.0/ http://creativecommons.org/licenses/by-nc-sa/4.0 2025-05 68 pages Maddock, Koos Ermanoski, Ivan Miller, James Ali, Natalia Barrett, The Honors College Mechanical and Aerospace Engineering Program This thesis presents the development and refinement of a scalable manufacturing process for redox-active rings used in the Labyrinth Reactor (LR), a system designed for continuous solar thermochemical hydrogen (STCH) production. These rings are responsible for carrying out high-temperature redox cycles, and their geometry, structural integrity, and thermal performance are critical to the reactor’s efficiency and operation. Three manufacturing approaches were explored: pellet pressing, hand-pressed molding, and ceramic injection molding (CIM). Each method was evaluated through iterative testing to improve ring quality, reproducibility, and production throughput. While pellet pressing proved unsuitable due to fragility and geometric limitations, hand-pressed molding enabled the creation of fully formed rings with integrated spacers and central holes. However, the method was labor-intensive and difficult to scale. CIM emerged as the most promising technique, offering the ability to produce complex ring geometries in a single step with minimal post-processing. Through multiple design iterations, a successful CIM-based process was established, culminating in a mold capable of producing rings compatible with both ceria and calcium cerium titanium manganese oxide (CCTM). The final design supports key reactor requirements and provides a foundation for scalable ring production. While further development is required, including the use of metal molds and thermal shock testing, the work presented here demonstrates a viable path toward mass manufacturing of redox rings for next-generation hydrogen production systems. Sustainable Hydrogen Production Hydrogen Manufacturing and Development Ceramic Injection Molding Redox Active Material metal oxide Solar Thermochemical Hydrogen Development and Manufacturing of a Redox-Active Element for Sustainable Thermochemical Hydrogen Production