Formulation for 3D printing: Creating a plug and play platform for a disruptive UK industry

Lead Research Organisation: University of Nottingham
Department Name: Div of Process and Environmental Eng

Abstract

3D printing lacks the materials required to fully become an established mass manufacturing process. Progress in materials development continues but a step change is required, and this will be realised through high throughput methods. High throughput discovery is an established methodology for automated identification of promising materials. At Nottingham it has been developed as tool for understanding biomaterials, and recently was instrumental in finding materials whose surface would resist bacterial attachment, potentially avoiding unnecessary use of antibiotics. Here, drawing together a multi-disciplinary, cross-community team, we will adapt this philosophy to rapidly identify formulations that can be used for 3D printing in a range of sectors represented by our industry partners. This will enable the creation of a library of materials, material combinations and formulations that are proven for 3D printing (particularly ink jet, extrusion, hot melt extrusion). Whilst the formation of this methodology is an initially challenging and time consuming step, the establishment of this set of libraries will enable rapid adoption downstream whilst the methodology itself can be utilised by other sectors seeking materials. Our libraries will be readily extended to create a tool for UK industry for selection of 3D printing formulations.

Planned Impact

The main beneficiaries of this research will be the users and manufacturers of 3D printing equipment. To date, there has been limited choice of material for 3D printing, so whilst the future for 3DP is exciting, many of the desired objects are unable to be realised owing to an incomplete set of materials. Our aim is to rapidly identify promising materials for 3DP, determining the key sector specific properties and tabulating this in a readily available library.
The immediate beneficiaries of the work will be users of 3D printed products (represented across sectors by our industry partners), who will be able to use the sector specific library, and in future the validated high throughput methodology to produce 3D printable formulations without requiring significant resources - the company will be able to 'plug and play' when selecting materials for formulations.
This impact will be translated from the laboratory and through higher TRL levels through, for example, CPI, The National Formulation Centre and the proposed Medicines Manufacturing Innovation Centre.
Academic Beneficiaries will include research groups using 3D printing having a platform system for investigating highly sector specific research interests.
The ultimate beneficiaries will be consumers and users. The uptake of 3D printing offered by the widening of materials through design of formulations, will mean better and more efficacious products will be able to be produced. In the sectors with which we have chosen to engage, this will mean drug delivery systems tailored to patient, more environmentally friendly agrochemical application, engineering focused products that meet stringent materials properties requirements, home care products that are effective cleaning systems and more nutritious food.

Publications

10 25 50

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Ruiz-Cantu L (2021) Bespoke 3D-Printed Polydrug Implants Created via Microstructural Control of Oligomers. in ACS applied materials & interfaces

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He Y (2021) Exploiting Generative Design for 3D Printing of Bacterial Biofilm Resistant Composite Devices. in Advanced science (Weinheim, Baden-Wurttemberg, Germany)

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Vadodaria S (2020) Fabrication of surfactant-polyelectrolyte complex using valvejet 3D printing-aided colloidal self assembly in Colloids and Surfaces A: Physicochemical and Engineering Aspects

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Parker M (2017) Mutual Complexation between p-p Stacked Molecular Tweezers in Crystal Growth & Design

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Salimi S (2019) Property enhancement of healable supramolecular polyurethanes in European Polymer Journal

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Gholamipour-Shirazi A (2019) Designing hydrocolloid based food-ink formulations for extrusion 3D printing in Food Hydrocolloids

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Kamlow M (2021) 3D printing of kappa-carrageenan emulsion gels in Food Hydrocolloids for Health

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Gholamipour-Shirazi A (2020) How to Formulate for Structure and Texture via Medium of Additive Manufacturing-A Review. in Foods (Basel, Switzerland)

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Gholamipour-Shirazi A (2021) Dual stimuli-sensitive carrageenan-based formulation for additive manufacturing. in International journal of biological macromolecules

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Rodriguez-Salvador M (2019) Revealing emerging science and technology research for dentistry applications of 3D bioprinting. in International journal of bioprinting

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Cader HK (2019) Water-based 3D inkjet printing of an oral pharmaceutical dosage form. in International journal of pharmaceutics

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Khaled SA (2018) 3D extrusion printing of high drug loading immediate release paracetamol tablets. in International journal of pharmaceutics

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Clark E (2017) 3D printing of tablets using inkjet with UV photoinitiation in International Journal of Pharmaceutics

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Ding J (2021) The economics of additive manufacturing: Towards a general cost model including process failure in International Journal of Production Economics

 
Description This award has laid the basis for understanding how to rapidly identify materials that are suitable for 3D printing. It developed a high throughput systems based around a liquid handler that sped up the assessment of candidate materials by x15. It then took this method and applied it to the creation of medical implants, including multidrug implants and bacterial resistant prosthetics. It also adopted artificial intelligence processes to speed up the process even further. These advances were made over multiple sectors: pharma, food and biomedical.

Arising from this work have come key future research questions - how is it possible to determine what materials are useful for 3D printing? Can computational methods be deployed to speed up the process and even whether they can be used to circumvent practical experiments? Can we realise new products that have functionality not possible with other manufacturing methods as a consequence of this understanding of how to identify materials?
Exploitation Route This method has wide applicability to many sectors - it is an underpinning technology that can be applied to select and identify functional materials ready for 3D printing. These outcomes can be taken forward through further academic research, speeding up the process further, by other academic teams wishing to exploit faster ways of finding materials suitable for their research, and by companies who want to implement 3D printing within their manufacturing.
Sectors Aerospace, Defence and Marine,Agriculture, Food and Drink,Chemicals,Electronics,Energy,Environment,Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology

URL https://www.nottingham.ac.uk/research/groups/cfam/major-epsrc-funding/index.aspx
 
Description Our findings have been used to inform our Sector partners in the development of materials for additive manufacture. This has included Unilever, GSK, Malvern Instruments, PPG Inc and Syngenta. Further, these findings have now begun to find use outside of our original partners. Firstly, the findings are being translated via the University of Nottingham spin out, Added Scientific Ltd, to the UK sector and beyond, supporting the development of 3D printing materials for its own business and for its clients. Secondly, a new set of partners is being connected with, including AZ, Pfizer, Formlabs and Johnson Matthey, all of whom wish to explore how this technology can be used to assist the adoption of 3D printing into their companies.
First Year Of Impact 2017
Sector Agriculture, Food and Drink,Chemicals,Digital/Communication/Information Technologies (including Software),Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology
Impact Types Economic

 
Description 3D Printing for World Class Additive Biofabrication
Amount £964,323 (GBP)
Funding ID EP/V036025/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 11/2020 
End 05/2022
 
Description Accelerated Discovery and Development of New Medicines: Prosperity Partnership for a Healthier Nation
Amount £5,495,023 (GBP)
Funding ID EP/S035990/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2019 
End 12/2023
 
Description Accelerating commercialization of the Nottingham reactive 3D printing process (IAA - Impact Acceleration Account )- YH
Amount £24,875 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2021 
End 02/2022
 
Description Dialling up performance for on demand manufacturing
Amount £5,865,536 (GBP)
Funding ID EP/W017032/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2022 
End 09/2027
 
Description MRC Confidence in Concept Award (CiC): Preparing for first in man trials of 3D printed solid dosage forms
Amount £76,083 (GBP)
Organisation Medical Research Council (MRC) 
Sector Public
Country United Kingdom
Start 01/2020 
End 01/2021
 
Description MSk MEC and UKRMP Smart Materials Hub Sandpit competition- Development of a fatigue detection device to prevent musculoskeletal injuries in football (LRC)
Amount £14,900 (GBP)
Organisation Wellcome Trust 
Sector Charity/Non Profit
Country United Kingdom
Start 11/2019 
End 06/2020
 
Description MSk MEC and UKRMP Smart Materials Hub Sandpit competition: Mechano-chemical integration at the osteochondral interface (LRC)
Amount £14,900 (GBP)
Organisation Wellcome Trust 
Sector Charity/Non Profit
Country United Kingdom
Start 11/2019 
End 06/2020
 
Description Nottingham UNICAS: Tea for two-photon polymerisation (EC, QH, LS)
Amount £12,133 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 04/2019 
End 07/2019
 
Description Y He - Visiting Researcher Fellowship (UoSeville)
Amount € 9,000 (EUR)
Organisation University of Seville 
Sector Academic/University
Country Spain
Start 10/2018 
End 11/2018
 
Title High throughput ink jet printability test 
Description We have developed a high throughput ink jet printability test that identifies materials with viscosity and surface tension within range of printability. 
Type Of Material Improvements to research infrastructure 
Year Produced 2018 
Provided To Others? No  
Impact None as of yet. 
 
Description Collaboration with Formlabs 
Organisation Formlabs
Country United States 
Sector Private 
PI Contribution Materials development
Collaborator Contribution 3D printing
Impact No outcomes yet.
Start Year 2021
 
Description DFE Pharma 
Organisation DFE Pharma
Department DFE Pharma Netherlands
Country Netherlands 
Sector Private 
PI Contribution Materials development
Collaborator Contribution Pharmaceuticals research
Impact None
Start Year 2020
 
Description GSK Dosage Forms 
Organisation GlaxoSmithKline (GSK)
Department GlaxoSmithKline, Stevenage
Country United Kingdom 
Sector Private 
PI Contribution Partnering with GSK to understand how 3D printing can be used to create solid dosage forms.
Collaborator Contribution Partnering with UoN to understand how 3D printing can be used to create solid dosage forms.
Impact Further collaborative projects have emerged.
Start Year 2016
 
Description NDA with Hamilton Robotics Company 
Organisation Hamilton Company
Country United States 
Sector Private 
PI Contribution NDA is signed between the University of Nottingham and Hamilton Robotics to establish collaboration between both sides on development of a liquid handling station on screening inkjet formulations. We disseminate their equipment and software in the journal and conference publications.
Collaborator Contribution Hamilton Robotics can provide technical support to our research using their equipment and also offer discount on the purchase of their equipment
Impact We have demonstrated some new capability of their equipment to measure viscosity and surface tension. Hamilton Robotics have offered discount on the purchase of their liquid handler. We have submitted a journal manuscript to Additive Manufacturing and will present related work on a conference during 4th - 6th March 2019. These activities will disseminate their equipment.
Start Year 2018
 
Title Reactive Pro-Drug Formulation 
Description The present invention relates to methods of producing solid drug formulations and to solid drug formulations 
IP Reference PCT/GB2021/050227 
Protection Patent application published
Year Protection Granted 2021
Licensed No
Impact None
 
Description A Konta -participation in 'Family Discovery Day' 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact A Konta attended the outreach event 'Family Discovery Day at the University of Nottingham. The activity was called: "Plastics Vs Cells: Will the Super Bugs Win?" Children and parents entered into a battle of cells Vs plastics, trying to find the right material for the right cells.The event ws attended by more than 370 visitor. All the comments from the visitors were positive, the children seemed to love the activities.
Year(s) Of Engagement Activity 2018
 
Description Britest Keynote 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact A keynote talk to the organisation 'Britest'
Year(s) Of Engagement Activity 2021
 
Description KTN Workshop on additive biofabrication 
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 A dissemination event to inform business on the role of additve manufacturing in regenerative medicine.
Year(s) Of Engagement Activity 2020
 
Description L Hart - Advanced Polymers via Macromolecular Engineering 2017 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact L Hart, (UoR) made a poster presentation at the Advanced Polymers via Macromolecular Engineering, poster title: Inkjet Printable Supramolecular Polymers: From 2D to 3D. The focus of the APME2017 meeting was on macromolecular engineering for the design of advanced polymeric structures, in connection to their characterisation and recent applications.
Year(s) Of Engagement Activity 2017
 
Description L Hart - RSC Organic Division South-West Regional Meeting 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact L Hart (UoR), was a speaker at the RSC Organic Division South-West Regional Meeting. His presentation title was: Supramolecular Polymer Networks: Healable and Printable Materials.This meeting celebrated and showcased the organic chemistry conducted in the South West, with speakers who enthralled and educated the attendees on areas of current study in the South West.
Year(s) Of Engagement Activity 2017
 
Description L Hart - poster presentation at the Recent Appointees in Polymer Science 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact L Hart made a poster presentation at the Recent Appointees in Polymer Science, Inkjet Printable Supramolecular Polymers: From 2D to 3D. Recent Appointees in Polymer Science (RAPS) is a network for young academic and industrial scientists working in any area of polymer science.
Year(s) Of Engagement Activity 2017
 
Description L Hart -Presentation at Supramolecular Polymer Networks- PLEASE CHECK 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact L Hart (UoR) made a presentation at the Supramolecular Polymer Networks, Healing and Beyond (8-9th October 2018), title AMI Self-Healing Materials
Year(s) Of Engagement Activity 2018
 
Description L Ruiz et al - poster presentation at Biofabrication 2018. 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact L Ruiz-Cantu, Z Zhou, V Taresco, D Irvine, R Hague, C Tuck and R Wildman,: poster presentation at the Biofabrication 2018, title: Formulating for 3D printing: high throughput formulation and screening of inks for 3D printing multi- functional drug delivery implants. The aim of the conference is to provide a broad communication platform for the multi-disciplinary community to enable researchers, clinicians and industry participants to exchange and disseminate the recent scientific discoveries, research activities, development and emerging applications in the field of Biofabrication.
Year(s) Of Engagement Activity 2016,2018
 
Description L Ruiz et al: poster presentation at the Macro Group UK Young Research Meeting 2017 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact L Ruiz-Cantu made a presentation at the Macro Group UK Young Research Meeting, titled Synthetic biodegradable formulations for inkjet 3D printing personalised drug-eluting implants obtained by the combinatorial synthesis and high throughput screening of UV cross linkable polymers.
Year(s) Of Engagement Activity 2017
 
Description R Wildman - Presentation at RSC Future Formulation Event 
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 R Wildman made a presentation at the RSC Future Formulation Event, on the research project , 'Formulation for 3D Printing' .
This is a recurring event, which took place at the University of Durham (FF I in 2017) and University of Nottingham (FF II in 2018).
Year(s) Of Engagement Activity 2017,2018
 
Description R Wildman - Presentation at CMAC Future Manufacturing Research Hub 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact R Wildman, R. made a presentation at CMAC Future Manufacturing Research Hub, Strathclyde University, Glasgow, 'Advances in 3D Printing (with a healthcare perspective)'. The presentation was followed by questions on project progress.
Year(s) Of Engagement Activity 2017
 
Description R Wildman - Presentation at Irish Polymers and Materials Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact R Wildman made a presentation at the Irish Polymers and Materials Conference, IT Tallaght Dublin, 'Formulation for 3D Printing - challenges and solutions' .
This conference, organised jointly by the SCI All Ireland Group and Materials Chemistry Group,looked at recent advances in materials for AM plus what are still seen as unmet needs. This was the first Irish conference on materials for AM and will be relevant to academics and industrialists, both Irish and International.
Year(s) Of Engagement Activity 2017
 
Description R Wildman - presentation at Additive International conference 
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 R Wildman and Ff3DP team attended the Additive International conference. He made a presentation with title: 'Materials: the more the merrier!' The conference was attended by more than 360 delegates and exhibitors from 20 countries. The participation to the event contributed to start of building new relationship with other researchers in the field.
Year(s) Of Engagement Activity 2018
 
Description RW: Presentation at Formnext International Exhibition 
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 R Wildman made a presentation at Formnext International Exhibition, Frankfurt, '3D Printing of Pills' (Nov 2018).Formnext is a leading exhibition and conference dedicated to additive manufacturing and all of its upstream and downstream processes. The presentation led to follow on enquiries on research carried out in the project.
Year(s) Of Engagement Activity 2018
 
Description Royal Society Summer Exhibition 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Schools
Results and Impact Royal Society Summer Exhibition is an annual event held at the Royal Society designed to reach out to the public on subjects of high interest.
Year(s) Of Engagement Activity 2019,2020,2021
 
Description Royal Society Summer Exhibition- 2021 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact The Formulation for 3D printing team had the exciting opportunity to be part of the "Summer Science hub" at the Royal Society Summer Exhibition 2021 with the theme "Can we print your perfect pill". We made a movie1, a virtual game3 and a lightning lecture2, with contributions across the team, allowing the public to take a virtual step into our lab and learn about how, and why, we are working to create 3D printed medicine.
With our movie we told the story of how polypills can lighten the pill burden, while with our game we put the player in the shoes of a pharmacist who has to manage a queue of patients! Our lightning lecture was seen by over 16000 people and was hosted by Dr Ruiz Cantu and Dr He who told the story of why we need to 3D print tablets.
During the exhibition, we were delighted to talk about our research with BBC Radio 4 programme 'Inside Science', with BBC Radio Nottingham and a spot on Al Jazeera English TV.
www.youtube.com/watch?v=m4nUbSjKslI&ab_channel=TheRoyalSociety
https://www.youtube.com/watch?v=C05tBuY2PEw&list=PLg7f-TkW11iVmGf4Sexj_akSICGQ6vyEa
https://limitless-beach-00824.herokuapp.com/
Year(s) Of Engagement Activity 2021
URL https://limitless-beach-00824.herokuapp.com/
 
Description Y He et al - presentation at the University of Cadiz 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact He Y., made a presentation at the University of Cadiz, title "The Application of 3D printing for biomedical device: high-throughput formulating and multi-functional AM process" (other authors from the University of Nottingham: Clark E.A., Khaled S., Ruiz-Cantu, L., Zhou Z., Irvine D., Robert C., Hague R., Tuck C., Wildman R).
The presentation was very well received and plans for future collaboration were made.
Year(s) Of Engagement Activity 2018
 
Description Y He et al- University of Seville presentation 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact He Y., Clark E.A., Khaled S., Ruiz-Cantu, L., Zhou Z., Irvine D., Robert C., Hague R., Tuck C., Wildman R. made a presentation at the University of Seville, title : "The Application of 3D printing for biomedical device: high-throughput formulating and multi-functional AM process". The presentation was followed by discussions,the researchers at the Seville University were interested in future collaboration and currently a research publication is in progress.
Year(s) Of Engagement Activity 2018
 
Description Z Zhou - invited lecture at De Montfort University 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Undergraduate students
Results and Impact Z Zhou was invited to give a lecture on 'Additive Manufacturing' for 1st-year Physics students in De Montfort University. Presentation was given to an audience of 23 students and it was followed by further questions and discussions.
Year(s) Of Engagement Activity 2017
 
Description Z Zhou et al- poster presentation at the Macro Group UK Young Research Meeting 2017 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Z Zhou made a presentation at the Macro Group UK Young Research Meeting, title: A Combinatorial Approach to Discover Polymer Formulations for Extrusion-Based Additive Manufacturing.
Year(s) Of Engagement Activity 2017