Photocatalysis is widely acknowledged as an efficient and environmentally friendly method for treating dye-contaminated wastewater. However, the utilization of powdered photocatalysts presents significant challenges, including issues related to recyclability and the potential for secondary pollution. Herein, a novel technique based on 3D printing for the synthesizing of iron oxide (Fe2O3) involving chlorella was presented. Initially, chlorella powders were immobilized within acrylonitrile butadiene styrene (ABS) and thermoplastic polyurethane (TPU) substrate plastics using melt extrusion technology. Subsequently, these composite materials were transformed into ABS/TPU/chlorella skeletons (ATCh40), through fused deposition molding (FDM) technology. The integration of Fe2O3 onto the ATCh40 (ATCh40-Fe2O3) skeletons was accomplished by subjecting them to controlled heating in an oil bath. A comprehensive characterization of the synthesized materials confirms the successful growth of Fe2O3 on the surface of 3D skeletons. This strategy effectively addresses the immobilization challenges associated with powdered photocatalysts. In photocatalytic degradation experiments targeting methyl orange (MO), the ATCh40-Fe2O3 skeletons exhibited a remarkable MO removal rate of 91% within 240 min. Under conditions where the pH of MO solution was maintained at 3, and the ATCh40-Fe2O3 skeletons were subjected to a heat treatment in a 150 °C blast drying oven for 2 hours, the degradation rate of MO remained substantial, achieving 90% removal after 6 cycles. In contrast, when the same synthetic procedure was applied to ABS/TPU (AT) skeletons, the resulting product was identified as α-FeOOH. The MO removal rate by the AT-α-FeOOH skeletons was considerably lower, reaching only 49% after 240 min. This research provided a practical approach for the construction of photocatalytic devices through the use of 3D printing technology.
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