dc.title: Additively manufactured dual-scale triply periodic minimal surface structures for modular Ion capture of critical elements dc.description.abstract: The escalating global demand for critical transition metals necessitates a fundamental paradigm shift in sustainable resource recovery. Traditional industrial ion-capture techniques, such as pyrometallurgy and conventional solvent extraction, are increasingly restricted by massive energy consumption, severe environmental toxicity, and fundamental mass transfer limitations inherent to solid state packed resin beds. To overcome these critical hydrodynamic and chemical bottlenecks, this dissertation engineers a highly scalable, continuous element recovery platform by synergistically integrating macroscopic Triply Periodic Minimal Surface (TPMS) architectures with nanoscopic functionalized porous resins. The investigation leverages rigorous computational fluid dynamics (CFD) simulations to optimize the macroscopic fluid domains. The gyroid architecture, scaled to a 6 mm unit cell, was identified as the superior topology for maximizing the fluid mixing while minimizing the operational pressure drop. To physically validate these optimized gyroid architecture, a highly reliable digital light processing (DLP) additive manufacturing protocol was developed. A highly resilient custom photopolymer matrix was specifically engineered to withstand continuous hydrodynamic cycling. Crucially, the successful covalent integration of receptor into this highly interconnected nanoporous backbone enabled the highly specific chemical coordination of target transition metals. Comprehensive dynamic flow evaluations provided unequivocal empirical validation of the engineered modules. Continuous element absorbing tests revealed a highly advantageous bimodal extraction mechanism, where the intrinsic physical porosity amplified the total capture capacity substantially beyond the theoretical chemical limits. Subsequent element release evaluations demonstrated exceptionally rapid desorption kinetics. The analytical accuracy of the highly convenient continuous electrical conductivity tracking methodology was rigorously verified via direct Inductively Coupled Plasma cross validation, yielding a near perfect coefficient of determination. Ultimately, demanding multi-element ion-capture tests proved the exceptional selective filtration capabilities of the 3D printed devices, successfully isolating high value cobalt and nickel ions while entirely rejecting non-targeted manganese species within complex mixed fluid streams. By fundamentally resolving the severe mass transfer and pressure drop limitations of traditional systems, these additively manufactured dual scale structures present a transformative and highly viable technological pathway for the future of sustainable industrial hydrometallurgy.