Manufacturing with Light 2: Photobioform II
Lead Research Organisation:
University of Leeds
Department Name: Mechanical Engineering
Abstract
Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.
Publications
Wilkinson N
(2019)
A review of aerosol jet printing-a non-traditional hybrid process for micro-manufacturing
in The International Journal of Advanced Manufacturing Technology
Shuttleworth MP
(2018)
A new digitally driven process for the fabrication of flex-rigid electronics
Ryspayeva A
(2019)
Selective Electroless Copper Deposition by Using Photolithographic Polymer/Ag Nanocomposite
in IEEE Transactions on Electron Devices
Ryspayeva A
(2019)
A rapid technique for the direct metallization of PDMS substrates for flexible and stretchable electronics applications
in Microelectronic Engineering
Ryspayeva A
(2019)
Selective Metallization of 3D Printable Thermoplastic Polyurethanes
in IEEE Access
Marques-Hueso J
(2020)
Spinach-based photo-catalyst for selective plating on polyimide-based substrates for micro-patterning circuitry
in Chemical Engineering Research and Design
Marques-Hueso J
(2018)
Flexible Electronics: A Rapid Photopatterning Method for Selective Plating of 2D and 3D Microcircuitry on Polyetherimide (Adv. Funct. Mater. 6/2018)
in Advanced Functional Materials
Marques-Hueso J
(2017)
A Rapid Photopatterning Method for Selective Plating of 2D and 3D Microcircuitry on Polyetherimide
in Advanced Functional Materials
Jones T
(2019)
Direct metallisation of polyetherimide substrates by activation with different metals
in Surface and Coatings Technology
Hinton J
(2019)
Hybrid additive manufacturing of precision engineered ceramic components
in Rapid Prototyping Journal
| Description | The initial speculative feasibility project (Photobioform I - EP/L022133/1) made new scientific breakthroughs and demonstrated the proof of concept around a highly novel concept of 'Green synthesis' methods which can selectively metallise a range of planar, flexible or 3D plastic parts with metal nanoparticles. This new manufacturing approach has 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. The phase II grant which was secured from this project is to further develop this work and generate industrially-driven proof of concept demonstrators. New UK Industrial partners have been brought into to further accelerate impact of this research including Renishaw and Blatchford. Application areas in 3D encoders and smart prosthetics will be developed during this project to demonstrate the impact of this newly developed manufacturing process chain. |
| Exploitation Route | The approach to selectively metalise 3D printed polymer parts has application areas for further development in: - electronics manufacture - sensor systems - antimicrobial coatings - smart prosthetics - a new manufacturing strategy for robotics systems, medical devices and wearable technology. |
| Sectors | Electronics,Healthcare,Manufacturing, including Industrial Biotechology |
| Description | In order to achieve the functionality, miniaturization and reliability of modern electronics systems 3D printing approaches urgently require further innovation in materials and manufacturing processes. This project has developed a new transformative digital fabrication strategy that provides the required mechanical, electrical, thermal and electromagnetic properties for future real-world applications in the fields of electronics, robotics, medicine and communications. This has been achieved by combining 3D printing of high performance polymers (Polyetherimide), light-based selective metallisation of copper traces, and computer-controlled assembly of functional devices and structures. Using this approach, the project has demonstrated high resolution conductive circuitry across flexible and conformal surfaces omitting the need for separate printed circuit boards (PCBs). This research has show how the process is compatible with existing high reliability electronic packaging approaches by surface mount assembling a range of components using solder interconnects. To demonstrate this new capability, devices were manufactured including a highly flexible positional sensor, a pill capsule capable of high frequency wireless communication, and an inductive powering coil for portable and wearable devices. The approach has also demonstrated successful actuation through selective heating of shape memory alloy materials which could provide future new methods for producing complex micromachines and tuneable metadevices. The outputs from this project have also helped secure direct industry funding with Kanthal a global provider of electrical heating technology. |
| First Year Of Impact | 2018 |
| Sector | Aerospace, Defence and Marine,Electronics,Energy,Environment,Healthcare,Manufacturing, including Industrial Biotechology |
| Impact Types | Societal,Economic |
| Description | A Platform for Hybrid Manufacturing Process research |
| Amount | £1,675,629 (GBP) |
| Funding ID | EP/P027687/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2017 |
| End | 06/2022 |
| Description | Advanced Machinery & Productivity Institute (AMPI) |
| Amount | £22,600,000 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 10/2021 |
| End | 09/2026 |
| Description | Acting as an external supervisor for the Phd programme in Medical Nanotechnology of the European School of Molecular Medicine and of the University of Milano |
| Organisation | University of Milan |
| Country | Italy |
| Sector | Academic/University |
| PI Contribution | Dr. Kay provides external guidance and mentoring to a PhD student at the University of Milano who is working on a multidisciplinary research project. Dr, Kay specifically provides technical supervision around the manufacturing processes aspects of the research. |
| Collaborator Contribution | The Phd programme in Medical Nanotechnology of the European School of Molecular Medicine is funded by the European Commission. This specific multidisciplinary PhD the project partners particularly provide a range of scientific and technical input specifically materials science expertise. |
| Impact | New multi-disciplinary research ideas. |
| Start Year | 2016 |
| Description | Direct industry funding for additive manufacture of electrical heating technology |
| Organisation | Kanthal |
| Country | Sweden |
| Sector | Private |
| PI Contribution | We have developed a new manufacturing process and machinery for Kanthal to research the development of complex and efficient electrical heating technology. |
| Collaborator Contribution | Funding for Post Doctoral Researcher time, 2 X PhD studentship, £50,000 of consumables, £5,000 travel, technical staff time, industrial mentoring, access to testing facilities, factory visits and secondments for researchers. |
| Impact | Multi-disciplinary collaboration of materials and manufacturing to improve the production capabilities of the industrial partner. The products will aid the manufacturing industry using industrial thermal processing operations to transition away from fossil fuels. This has been achieved by developing a production process (and associated machinery) that can generate complex 3D parts that have the required characteristics for industrial heating. |
| Start Year | 2020 |
| Description | Additive Manufacturing and 3D printing workshop |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | The International Microelectronics and Packaging Society (IMAPS) Workshop on Additive Manufacturing (printing) for packaging was hosted by Dr. Robert Kay at Loughborough University on the 22nd October 2015. This workshop brought together a range of individuals primarily from industry in order to introduce them to the current developments and activities in 3D printing applied to the field of electronics. The workshop was split into a morning session which educated these new individuals into the field of Additive Manufacturing and then in the afternoon covered the latest developments in academia and industry around 3D printing for electronics manufacturing. The research findings from two EPSRC projects was also showcased at this event (EP/L017415/1 & EP/L022133/1). Besides the networking benefits from this event the investigators on this grant were able to establish new collaborations with industry on existing and future research activities. The event also raised the awareness of many of the research activities in this field currently being conducted by UK Universities. |
| Year(s) Of Engagement Activity | 2015 |
| URL | https://imapsuk.wordpress.com/2015/09/08/additive-manufacturing-and-3d-printing-workshop-programme-a... |
| Description | Design for 3D Printing Guest Lecture |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | Regional |
| Primary Audience | Professional Practitioners |
| Results and Impact | Invited talk to discuss how Photobioform I and II was applied to create 3D Printed electronics. The talk is from the Design for 3D Printing Guest Lecture series at Loughbourgh University. |
| Year(s) Of Engagement Activity | 2021 |
| Description | EPSRC Design for AM network presentation |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | The EPSRC Design for AM Network is seeking to bridge the gap between design and specific sectors of the Additive Manufacturing Industry. My presentation involved using examples from this Manufatguring with Light-based technique to overcome existing limitations. |
| Year(s) Of Engagement Activity | 2020 |
| URL | https://www.designforam.ac.uk/ |
| Description | Industry engagement event at Blatchford (world leading rehabilitation provider with clinical expertise in prosthetics, orthotics, special seating and wheelchairs) |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Professor Harris and Dr Kay visited Blatchford on 14th February 2018 to present their research in new manufacturing processes to management and engineering teams. This resulted in questions and discussion regarding how this related to current, emerging, and future devices for rehabilitation. |
| Year(s) Of Engagement Activity | 2018 |
| Description | Inspiring the next generation of students into Mechanical and Manufacturing Engineering. Smallpeice Trust event at University of Warwick for Year 12 Students, July 2017 |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Schools |
| Results and Impact | My aim was to deliver a talk that inspired students into engineering by me sharing my own personal experiences and research activities. The talk received many questions afterwards plus I received feedback by e-mail from some students thanking me for an enjoyable talk. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Invited Presentation at the National Physics Laboratory Manufacturer Measurement Network |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Presenting at the National Physics Laboratory Manufacturer Measurement Network (MMN) seminar. The MNN supports the UK manufacturing supply chain by disseminating information, sharing best practise and offering training. My talk was to talk about the outputs of the Photobioform II project which enabled the creation of high-performance 3D printed electronics. |
| Year(s) Of Engagement Activity | 2023 |
| Description | Invited talk at Technical University Delft |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Postgraduate students |
| Results and Impact | Invited talk at the TU Delft Faculty of Industrial Design Engineering to present the research stemming from the outputs of this grant. |
| Year(s) Of Engagement Activity | 2022 |
| Description | Invited to the Additive Manufacturing BSI Committee |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Third sector organisations |
| Results and Impact | As a result of my work in developing new Additive Manufacturing processes including Photobioform I was invited to apply to stand on the British Standards Institute (BSI) Additve Manufacturing Technologies (AMT/8) committee. Our work also feeds into International standards including ISO and ASTM. |
| Year(s) Of Engagement Activity | 2021,2022 |
| URL | https://standardsdevelopment.bsigroup.com/committees/50226095#:~:text=Overview%3A%20Under%20the%20di... |
| Description | Preentation to the Medical Device Manufacturing Centre (Edinburgh) |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Professional Practitioners |
| Results and Impact | Informing the Medical Device Manufacturing community on the outputs from the Photobioform II project to widen update of the technology. |
| Year(s) Of Engagement Activity | 2020 |
| URL | http://mdmc.hw.ac.uk/ |
| Description | School Of Mechanical Engineering Seminar, 9th November 2017 Hybrid Additive Manufacturing of 3D Electronic Systems |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Professional Practitioners |
| Results and Impact | 30 individuals from the School of Mechanical Engineering Attended an Invited Colloquium where Dr. Robert Kay presented his portfollio of EPSRC funded research in the area of "Hybrid Additive Manufacturing of 3D Electronic Systems". This talk has sparked discussions to form new potential research collaborations in the field of Manufacturing Processes Research. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Speaker Invitation - Frontiers in Advanced Materials and Engineering Devices (FAMED) Northumbria research seminars |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Professional Practitioners |
| Results and Impact | Talk about research stemming from the Photobioform I and II project. |
| Year(s) Of Engagement Activity | 2022 |
| Description | Theme Lead in Electronics for ESRPC Design for Additive Manufacturing |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | Regional |
| Primary Audience | Industry/Business |
| Results and Impact | As a result of my work in EPSRC grants Photobioform and IAMP I was invited to speak at the ESPRC Design for AM launch event. The management committee thought my presentation demonstrated my leadership in the field of Additive Manufacturing for electronics and therefore asked me to lead their first theme. I am now theme Lead in 3D Printing of Electronics for the EPSRC Design for Additive Manufacturing network and in 2021 organised a 2 day online event which brought two communities together to identify and roadmap how to solve the grand challenges. Through this work we linked the International Microelectronics and Packaging Society with Design for AM members bridging the gap between the disciplines. We have now produced a technological roadmap that will help the community tackle the challenges facing this growing research area. The output from Photobio form is also the cover image for the EPSRC Design for AM network webpage: https://www.designforam.ac.uk |
| Year(s) Of Engagement Activity | 2021,2022 |
| URL | https://www.designforam.ac.uk/design-for-am-electronics-2/ |