A process for forming a fluidic module (150) with integrated fluid separation includes positioning a first positive passage mold (115A) of a first fluid passage (170) having a tortuous shape within a volume of binder-coated ceramic powder (110A) and positioning a second positive passage mold (115B) of a second fluid passage (175) having a tortuous shape within the volume of ceramic powder (110A) and spaced apart from the first positive passage mold (115A). The process further includes positioning a powder interconnect (120) adjacent to a portion of each of the first (115A) and second positive passage molds (115B) within the volume of ceramic powder (110A), pressing the volume of ceramic powder (110A, HOB) with the first and second positive passage molds (115A, 115B) and the powder interconnect (120) inside to form a pressed body (148), heating the pressed body to remove the first and second positive passage molds (115A, 115B), and sintering the pressed body (148) to form a closed-porosity ceramic body (150).

This monolithic reactor is an adaptable and scalable, flow-through reaction containment apparatus embodied as a one-piece monolithic block of material that retains re-configurability to improve reaction processing. This apparatus increases operational flexibility, adaptable design, and vastly simplifies construction of tubular reaction-containment configurations. Internally, the monolithic block comprises one or more closely spaced, functional voids which operate as fluid channels that can be configured in various geometric arrangements. The apparatus is widely scalable, provides high thermodynamic efficiency, manufacturing simplicity, and affordability for varied operations through additive manufacturing, and has a compact physical footprint.