A two-stage flow strategy for the synthesis of isobutyl-modified methylaluminoxane

We present a flow strategy, aided by 3D printing, to synthesize isobutyl-modified methylaluminoxane (Bu-i-MMAO) with high yield and superior co-catalytic activity for olefin polymerization. Our flow platform encompasses on demand designed module handling in series: (i) isobutylaluminoxane (IBAO) synthesis, (ii) reaction of IBAO and trimethylaluminum (TMA), and (iii) Bu-i-MMAO synthesis. The presented approach, which mitigates the risks of clogging in flow and thermal runaway, offers long term stability and inherent safety during operation, and is readily scaled up using multiple reactors.