Systems and methods for fabricating an air purification device for use typically with heating, ventilating, and air conditioning (HVAC) system are presented. The systems include at least one pleated insert disposed within a cartridge housing and proximate a source of electromagnetic radiation. The pleated insert includes a plurality of pleat strips aligned substantially parallel to a common pleat axis. Each pleat strip has a first edge and a second edge. Portions or surfaces proximate the first edge and the second edge of each pleat strip are bonded so as to form an alternating sequence of peaks and valleys. A photocatalytic material coats at least a portion of the pleated insert. Methods for fabricating the pleated insert from a slice member having an unexpanded honeycomb structure are also presented. Other systems and methods are presented.