PHOTOBIOFORM II

Selective formation of metallic nanoparticles in plastics has a wide range of uses for generating conductive tracks, creating antimicrobial surfaces and for the fabrication of sensors and actuators which has a broad spectrum of applications such as microsystems, printed electronics and wearable devices.

Photobioform II aims to develop bio-inspired, industrially relevant manufacturing processes that can selectively pattern metals onto non-conductive substrates using light-harvesting complexes to accelerate the reduction of metal ions embedded into these substrates. The key challenges addressed in this project cover the fields of material science and manufacturing.

The material science challenges include (1) the vast range of materials which can be processed using this method where each material requires different treatment techniques or operational parameters, (2) the need for a better understanding of the mechanisms responsible for the photosynthesis within the light harvesting complexes, (3) the determination of the optimal material formulation for this reduction processes and (4) the understanding of the interdependent factors (wavelength, intensity, etc) acting in this multi-dimensional design space to target the for optimum metallisation process.

The manufacturing challenges cover (1) the interplay between processes and manufacturing techniques (and equipment) to deliver these processes (2) the novel spray coating process using aerosol jetting and (3) the industrial need for high speed, high resolution and low cost photo-patterning techniques. Particular high impact applications of prosthetics and encoders will be used to demonstrate the manufacturing capabilities developed during this research.

This research is expected to generate significant commercial, technological and scientific impact for high value manufacturing industries. 'Green synthesis' methods which can selective metallise a range of planar, flexible or 3D plastic parts with metal nanoparticles have the potential to enable low cost, sustainable and environmentally friendly manufacturing processes for the production of metal tracks, antimicrobial surfaces, and electrochemical sensors and actuators, which can benefit a range of industrial applications.

Beyond the academic community, the beneficiaries of this research are:
- UK industry will benefit from this multi-disciplinary research through increased scientific knowledge in material science and high value manufacturing creating new applications areas and business models.
- The industrial partners will not only directly gain from the research developed in this project but also from the new relationships formed between the academic institutions and industrial partners which will continue well after the project has completed.
- Prosthetic providers will directly benefit from the new novel manufacturing developments allowing them to increase functionality and enable patient specific customisation.
- Patients. Approximately 5,000 to 6,000 limb amputations occur in the UK every year and globally an estimated 1 million annual limb amputations per annum occur. Individuals with missing limbs will benefit from the developments made in this field through the developments of improvement methods of manufacturing prosthetics producing bespoke solutions enabling the patient to achieve a better quality of life and improved rehabilitation times.
- Antimicrobial materials. According to the World Health Organisation (WHO), an estimated 801,000 children younger than 5 years of age perish from diarrhoea each year. Large impact in terms of better water sanitation for developed and developing countries is expected as a result of this work. In addition, antimicrobial coatings can be cheaply applied to a range of 3D surfaces, such as pipes, enabling major benefits for eliminating harmful microorganisms without the need for strong disinfectants or costly materials.
- UK skills base will directly benefit as a result of the training and development of the two skilled PDRAs and two PhDs qualified in areas of manufacturing technologies and material science.
- The public and Society - The process enables the UK to secure manufacturing against the increasing scarcity and increased costs of raw materials, energy and other resources through the reduction of process steps and material wastage, utilisation of natural products, benefiting the overall economy and environment. This new process will allow companies to reduce their manufacturing costs, increase their public image as "green companies" and increase their market share.