Enabling manufacturing of Functional Nanomaterials using SynBio

This year, the global demand for nanomaterial, which is already a multi-billion$ industry, will have grown 2.5-fold since 2012. Current nanomaterials production methods are at least 1000 times more wasteful when compared to the production of bulk and fine chemicals. Consequently there is an urgent need to develop green production methods for nanomaterials which can allow greater control over materials properties, yet require less energy, produce less waste (i.e. eco-friendly) and are cost-effective.

Nature produces more than 60 distinct inorganic nanomaterials (e.g. CaCO3, Fe3O4, silica) on the largest of scales through self-assembly under ambient conditions (biomineralisation). Although biological methods for nanomaterials synthesis (e.g. using microorganisms or complex enzymes) are effective in reducing environmental burden, they are expensive, inefficient and/or currently not scalable to industrial production.

We will adopt a synthetic biology (SynBio) approach, which is one of the EPSRC's core strategic themes, by harnessing the biological principles to design advanced nanomaterials leading to novel manufacturing methods. SynBio is a very powerful tool for the production of high-precision advanced functional nanomaterials and our approach marries two of the "8 great technologies for the future" ("Synthetic Biology" and "Advanced Nanomaterials"). Instead of using cells or microbes, our SynBio strategy uses synthetic molecules (SynBio additives) inspired from biomineralisation. SynBio produces a wide range of well-defined and tunable nanomaterials under mild (ambient) conditions, quickly and with little waste. Our SynBio approach offers the potential for high-yields, like the traditional chemical precipitation method, together with the precision, customisation, efficiency and low waste of biomineralisation.

The bulk of research on bioinspired synthesis of nanomaterials has been performed at small scales and, although there are good opportunities for developing nanomaterials manufacturing based on bioinspired approaches, there are no reports on larger-scale investigations. Adopting a bioinspired SynBio approach, this project will enable the controlled synthesis and scalability of silica and magnetic nanoparticles (SNP and MNP) which are worth ~$11 billion globally. These methods are far more amenable to scale-up and can truly be considered 'green'. This SynBio process can reduce the manufacturing carbon footprint (by >90%), thus providing a significant cost benefit to industry.

Successful completion of this research has the potential to benefit the UK industry, society and the environment, and also make impact internationally. This project combines new manufacturing technologies to challenge current methods and resource sustainability, and multi-scale modelling to develop new tools and methods, which directly align with the outcomes and ambitions of becoming a "Productive and Resilient Nation" (EPSRC's new delivery plan for 2016 and beyond). The project outcomes will form a knowledge and resource base, with potential to make large impacts to the reduction of costs of nano-products, emission-reduction and job-creation. This project will deliver world-class research hardware, software and training on green manufacturing methods. Each area is detailed below.

There will be a major economic and societal impact from large-scale green manufacturing of advanced nanoparticles. Currently, large-scale green manufacturing of nanomaterials does not exist. The outcomes of this project will enable the UK's leadership in green manufacturing of advanced functional materials and create jobs in the UK. This project's output will play a part in delivering more cost-effective, sustainable manufacturability for the UK, e.g. meeting 2050 CO2 reduction targets whilst securing supply. We have strong support from industry partners who are keen to commercialise the outcomes to design and manufacture specific nano-products.

Owing to unique environmentally friendly manufacturing using SynBio approach, there is the potential to help reduce energy costs, fossil fuel dependence and the use of toxic/hazardous chemicals compared to existing nanomaterials manufacturing. Green manufacturing can create new products with a much more diverse range of functionalities and properties. Green manufacturing will provide significant improvement in product quality and reduction in costs, thus giving industry partners advantages over their competitors. The outputs will also enable us to create/expand UK manufacturing-base, enter new markets and create additional jobs in the UK.

Research outcomes, when made available and delivered to public, will see one of the greatest impacts in coming years. We aim to achieve impact by delivering research outcomes to public and school community. The society will learn about sustainable manufacturing and its long-term positive impacts.