Development of coated silicon microneedles for vaccine smart patch
Lead Research Organisation:
Swansea University
Department Name: College of Engineering
Abstract
Project Aims
This project will develop the silicon etch process technology to scale up the microneedle fabrication process from 100mm diameter wafers to 150mm diameter wafers - enabling more microneedle chips to be produced at lower cost. The process will be optimised using silicon smoothing and improved photolithography processes. The project will incorporate a self-release etch step into the fabrication process, so that microneedles can be easily separated from the wafer into individual devices. The project will also develop new plasma coating techniques to coat the microneedle in thin films which may be water repellent or non-stick, insulating or metallic. This will be achieved using Chemical Vapour Deposition, Molecular Vapour Deposition and electroplating.
This will allow development of a range of microneedle products for a variety of health and cosmetic applications.
The research engineer will use the facilities at the Centre for Nanohealth and the new £90 million Centre for Integrative Semiconductor Materials (CISM). Additionally, as the semiconductor community in South Wales is expanding rapidly the research engineer will receive training and preparation skills highly appropriate to a career in the semiconductor industry.
Background
SPTS Technologies, a KLA company, designs, manufactures, sells, and supports etch, PVD, CVD and MDS capital equipment, providing advanced wafer processing technologies and solutions for the semiconductor and microelectronics industry. SPTS are experts in semiconductor film coatings, deposition and etch technology, their revenue generation is from equipment sales and support services supplied to customers in major foundries and IDMs servicing end-market applications including micro-electromechanical systems (MEMS), advanced packaging, LED, high-speed RF device IC's and power semiconductors. SPTS have a growing activity in technology and products related to BioMEMS and have been developing microneedle technology with Swansea University for drug and vaccine delivery applications.
SPTS Technologies - a global leader in wafer processing equipment for the semiconductor and related industries - have been working with Swansea University to apply novel deep-etch and deposition plasma process technology to Bio microelectromechanical systems (Bio-MEMS) and healthcare products.
http://www.semiconductor-today.com/news_items/2019/aug/asset-200819.shtml
One of these technologies is hollow silicon microneedles. They are the longest "out of plane", sharpest silicon microneedles in the world and have been demonstrated for insulin delivery and cell delivery.
https://www.bbc.co.uk/news/uk-wales-44546252
More recently, SPTS microneedles have been used in the development of a smart patch for vaccine delivery and detection of a successful response to the vaccine by the body.
https://www.bbc.co.uk/news/uk-wales-55548670
This could ultimately be used for vaccination and testing of vaccination efficacy for COVID and other viruses.
This project will develop the silicon etch process technology to scale up the microneedle fabrication process from 100mm diameter wafers to 150mm diameter wafers - enabling more microneedle chips to be produced at lower cost. The process will be optimised using silicon smoothing and improved photolithography processes. The project will incorporate a self-release etch step into the fabrication process, so that microneedles can be easily separated from the wafer into individual devices. The project will also develop new plasma coating techniques to coat the microneedle in thin films which may be water repellent or non-stick, insulating or metallic. This will be achieved using Chemical Vapour Deposition, Molecular Vapour Deposition and electroplating.
This will allow development of a range of microneedle products for a variety of health and cosmetic applications.
The research engineer will use the facilities at the Centre for Nanohealth and the new £90 million Centre for Integrative Semiconductor Materials (CISM). Additionally, as the semiconductor community in South Wales is expanding rapidly the research engineer will receive training and preparation skills highly appropriate to a career in the semiconductor industry.
Background
SPTS Technologies, a KLA company, designs, manufactures, sells, and supports etch, PVD, CVD and MDS capital equipment, providing advanced wafer processing technologies and solutions for the semiconductor and microelectronics industry. SPTS are experts in semiconductor film coatings, deposition and etch technology, their revenue generation is from equipment sales and support services supplied to customers in major foundries and IDMs servicing end-market applications including micro-electromechanical systems (MEMS), advanced packaging, LED, high-speed RF device IC's and power semiconductors. SPTS have a growing activity in technology and products related to BioMEMS and have been developing microneedle technology with Swansea University for drug and vaccine delivery applications.
SPTS Technologies - a global leader in wafer processing equipment for the semiconductor and related industries - have been working with Swansea University to apply novel deep-etch and deposition plasma process technology to Bio microelectromechanical systems (Bio-MEMS) and healthcare products.
http://www.semiconductor-today.com/news_items/2019/aug/asset-200819.shtml
One of these technologies is hollow silicon microneedles. They are the longest "out of plane", sharpest silicon microneedles in the world and have been demonstrated for insulin delivery and cell delivery.
https://www.bbc.co.uk/news/uk-wales-44546252
More recently, SPTS microneedles have been used in the development of a smart patch for vaccine delivery and detection of a successful response to the vaccine by the body.
https://www.bbc.co.uk/news/uk-wales-55548670
This could ultimately be used for vaccination and testing of vaccination efficacy for COVID and other viruses.
Planned Impact
The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/S02252X/1 | 01/10/2019 | 31/03/2028 | |||
| 2597783 | Studentship | EP/S02252X/1 | 01/10/2021 | 30/09/2025 | Megan McNamee |