Manufacturing of Large Format Osmotic Membrane Module

Project Update

In 2023, Porifera advanced the design and early production of its parallel format osmotic membrane module, transitioning from initial concepts to functional prototypes. The team successfully manufactured multiple PFO-200 elements that passed internal QA/QC checks and conducted extensive testing to evaluate performance and inform design improvements. Key outcomes included refining manufacturing processes to improve product integrity and consistency, as well as modifying and optimizing equipment to support reliable assembly. Following successful testing of single prototype elements, Porifera scaled production to fabricate additional prototypes and evaluated larger assemblies operating under parallel flow conditions representative of commercial systems, demonstrating the technology’s processing capabilities.

In 2024, Porifera completed Phase 1 Manufacturing Design and Build, establishing a semi-automated manufacturing line for initial production of PFO-200 membrane packets. This phase included facility preparation, equipment procurement, installation, commissioning, and initial process validation to enable low-rate initial production. The team also developed detailed specification sheets for the PFO-200 element and shared project progress through presentations at industry events such as the Membrane Technology Forum and the EPIC Symposium. Ongoing work focused on evaluating element performance, refining cleaning protocols, and advancing automation of the manufacturing line to improve consistency and prepare for scale-up in Phase 2.

In 2025, Porifera advanced into Phase 2 of the project, focusing on improving manufacturing processes, quality control, and scalability of its membrane module production. Building on the semi-automated manufacturing line established in Phase 1, the team implemented targeted equipment upgrades and process improvements, including automated solution preparation for QA/QC, enhanced temperature control, robotic adhesive dispensing, and expanded durability and endurance testing. These efforts were driven by lessons learned from earlier manufacturing challenges, such as adhesive inconsistencies, mold deformation, and performance variability, and resulted in more reliable, repeatable production processes. In parallel, Porifera progressed toward PFO-275 system-level integration by supporting the assembly and glue curing of PFO-200 elements and continuing validation of performance and cleaning protocols, positioning the technology for scalable, commercial deployment.