US Patent 11554364 Active metal catalyst

A method of forming a catalyst is provided herein. The method comprises combining a binder, a support, and an active metal to form a slurry composition. The method further comprises applying the slurry composition using an additive manufacturing process to form a green part. The method further comprises exposing the green part to heat at a temperature of from about 10° C. to about 150° C. to form the hardened part. The method further comprises applying a ceramic-based coating material to the hardened part to form the catalyst.