Dialling up performance for on demand manufacturing

Lead Research Organisation: University of Nottingham
Department Name: Faculty of Engineering

Abstract

3D Printing elicits tremendous excitement from a broad variety of industry - it offers flexible, personalised and on demand scalable manufacture, affording the opportunity to create new products with geometrical / compositional freedoms and advanced functions that are not possible with traditional manufacturing practices. 3D Printing progresses rapidly: for polymerics, we have seen significant advances in our ability to be able to manufacture highly functional structures with high resolution projection through developments in projection micro stereolithography, multimaterial ink jet printing and two photon polymerisation. There have also been exciting advances in volumetric 3DP with the emergence of Computational Axial Lithography and more recent work such as 'xolo'. Alongside these advances there has also been developments in materials, e.g., in the emergence of '4D printing' using responsive polymers and machine learning / AI on 3DP is beginning to be incorporated into our understanding. The impact of these advances is significant, but 3D printing technology is reaching a tipping point where the multiple streams of effort (materials, design, process, product) must be brought together to overcome the barriers that prevent mass take up by industry, i.e., materials produced can often have poor performance and it is challenging to match them to specific processes, with few options available to change this. Industry in general have not found it easy to adopt this promising technology or exploit advanced functionality of materials or design, and this is particularly true in the biotech industries who we target in this programme grant - there is the will and the aspiration to adopt 3D printing but the challenges in going from concept to realisation are currently too steep.

A key challenge stymying the adoption of 3D printing is the ability to go from product idea to product realisation: each step of the workflow (e.g., materials, design, process, product) has significant inter-dependent challenges that means only an integrated approach can ultimately be successful. Industry tells us that they need to go significantly beyond current understanding and that manufacturing products embedded with advanced functionality needs the capability to quickly, predictably, and reliably 'dial up' performance, to meet sector specific needs and specific advanced functionalities. In essence, we need to take a bottom-up, scientific approach to integrate materials, design and process to enable us to produce advanced functional products. It is therefore critical we overcome the challenges associated with identifying, selecting, and processing materials with 3DP in order to facilitate wider adoption of this pivotal manufacturing approach, particularly within the key UK sectors of the economy: regenerative medicine, pharmaceutical and biocatalysis.

Our project will consider four Research Challenges (RCs):
PRODUCT: How can we exploit 3D printing and advanced polymers to create smart 21st Century products ready for use across multiple sectors?
MATERIALS: How can we create the materials that can enable control over advanced functionality / release, that are 3D Printable?
DESIGN: How can we use computational / algorithmic approaches to support materials identification / product design?
PROCESS: How can we integrate synthesis, screening and manufacturing processes to shorten the development and translation pipeline so that we can 'dial up' materials / properties?

By integrating these challenges, and taking a holistic, overarching view on how to realise advanced, highly functional bespoke 3D printed products that have the potential to transform UK high value biotechnology fields and beyond.
 
Description A biopesticidal lease of life for crop protection : additive manufacturing for tailored timing of biopesticide release by natural triggers
Amount £129,319 (GBP)
Funding ID BB/X005399/1 
Organisation Biotechnology and Biological Sciences Research Council (BBSRC) 
Sector Public
Country United Kingdom
Start 06/2022 
End 07/2023
 
Description Industrial Collaboration Programme (ICP)
Amount £88,533 (GBP)
Funding ID EP/X527257/1 
Organisation Henry Royce Institute 
Sector Academic/University
Country United Kingdom
Start 09/2023 
End 03/2024
 
Description RSC EDI funding: Socioeconomic Inclusion Special Call 2023 (VCC)
Amount £5,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 09/2023 
End 12/2024
 
Description Researcher Development and Travel Grant (Seminar and visit collaborators at 'Sapienza' University of Rome)
Amount £500 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 08/2023 
End 10/2023
 
Description UNICAS - Supporting cross-disciplinary research (internal funding): Developing microneedle for wound healing using two-photon photopolymerisation
Amount £5,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 03/2023 
End 07/2023
 
Description University of Nottingham: EPSRC Impact Acceleration Account
Amount £56,265 (GBP)
Funding ID Second line material for Reactive Jetting 
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 01/2023 
End 09/2023
 
Description University of Nottingham: EPSRC Impact Acceleration Account (RO)
Amount £36,600 (GBP)
Funding ID Advancement of research on Next Generation Bone Graft Substitutes towards commercialisation 
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 02/2024 
End 01/2025
 
Description UoN Equipment: Pipeline MergeOne (RW)
Amount £56,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 12/2023 
End 03/2024
 
Title Eco-friendly fungicide (VCC) 
Description A material that could replace current fungicides (i.e. anti-fungal pesticides), increase food security, and help protect wildlife has been discovered (https://www.nottingham.ac.uk/news/eco-friendly-fungicide-alternative-discovered-by-nottingham-researchers). 
Type Of Material Biological samples 
Year Produced 2024 
Provided To Others? Yes  
Impact Researchers at the University of Nottingham have completed a successful field trial of a material they have developed to help to protect crops from fungi. Coverage on: Phys.org, Mirage News, Food & Drink International, Sky, Technology Networks and Farmers guardian, Green Chemistry 
 
Description 3D-Printing of SERS sensor using two-photon photopolymerisation (KJ with JI/UoWarwick) 
Organisation University of Warwick
Country United Kingdom 
Sector Academic/University 
PI Contribution 3D-printing and characterisation of micro-arrays.
Collaborator Contribution Analysing Effect of the printed arrays on sensitivity of SERS
Impact Enhance sensitivity of Raman SERS electrode by creating high surface area electrode using high-precision 3D-printing
Start Year 2023
 
Description Collaboration with UC Berkeley to use VAM for vascularisation 
Organisation University of California, Berkeley
Country United States 
Sector Academic/University 
PI Contribution We are exchanging and hosting researchers to work together to solve a challenging issue.
Collaborator Contribution Our partners are hosting researchers from the project.
Impact None
Start Year 2023
 
Description ToF-SIMS analysis of multimaterial printed Proteins (GelMA)- KJ 
Organisation National Physical Laboratory
Country United Kingdom 
Sector Academic/University 
PI Contribution Multimaterial printing of protein
Collaborator Contribution ToF-SIMS analysis of multimaterial printed Proteins (GelMA)
Impact High-resolution additive manufacturing enables rapid production of diverse micro-needle geometries with features like barbs for improved skin retention and controlled drug release.
Start Year 2023
 
Description 2023 Cambridge Bioelectronics Symposium 
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 Organised the Cambridge Bioelectronics Symposium, an event that combined comprehensive coverage of the state-of-the-art of the field with strong participation of young scientists (graduate students/postdocs), hands-on workshops, and career furthering opportunities. It offered:

Coverage of fundamentals, materials, devices, applications, translation/commercialisation, ethical issues.
Invited talks by world-class experts who convey their vision for the future of the field.
Majority of contributed talks and posters presented by young scientists, selected by a committee of young scientists.
Hands-on demonstrations: Interested in bioelectronics but do not know where to start? These demonstrations will give you some good ideas.
Thematic panel discussion or road mapping exercise - more on this soon.
"Meet the industry" session. Learn about startups in the field.
Awards for best contributed talk and poster, selected by a committee of young scientists.
Symposium dinner.
Year(s) Of Engagement Activity 2023
URL https://bioelectronics.eng.cam.ac.uk/symposium-information
 
Description Engineering Research Future (ERF) Committee (VCC member of the committee) 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact Contribute ideas of how to create an excellent environment for our researchers, share any best practice and challenges from their groups, and to communicate relevant information or events to their groups
Year(s) Of Engagement Activity 2023
 
Description Festival of Science and Creativity (FOSAC) - Outreach event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Engaged with school groups in a science festival, demonstrating our research to kids interested in STEM. Made students and teachers aware of our research and increased their opinion of our group/institution.
Year(s) Of Engagement Activity 2024
 
Description High Polymer Research Group 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact National conference where developments in polymer science and engineering are made available and fully discussed by industrial and academic researchers engaged in the field.
The theme of the HPRG 2023 was 'Polymer in Water' which was of high relevance for the development of new materials for the bioreactor.
Year(s) Of Engagement Activity 2023
 
Description Materials Research Society Conference in Boston 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact RMO gave a plenary presentation (Kavli sponsored Symposium X talk). This is one of the lectures that does not occur at the same time as the parallel symposium sessions and so had a potential audience of ~5000. Approximately ~800 people attended. RMO gave an overview of the organ on chip technology that is the subject of this Proof of Concept grant. The talk she gave is summarised here: https://materials.typepad.com/mrs_meeting_scene/symposium-x/
She also gave a more technical talk (on the same subject) to a smaller group of people at the same conference - more focussed on organic bioelectronics ~40 people attended.
Year(s) Of Engagement Activity 2023
URL https://www.youtube.com/watch?v=5t7xx6wDUvI
 
Description Nucleate UK pitch 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Supporters
Results and Impact KK made a pitch to the Nucleate UK accelerator. A student led organisation that represents a global community of bio innovators. The pitch was to have access to the accelerator and seed funding. Unfortunately the pitch wasn't successful, however the experience was invaluable and helped shaped future pitches. KK applied for, and was successful in, joining the Innovate iCURE program - first explore and now exploit.
Year(s) Of Engagement Activity 2023
URL https://nucleate.xyz/
 
Description Plenary presentation - Micro Nano 2023 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Gave plennary presentation at Micro Nano meeting
Year(s) Of Engagement Activity 2023
URL https://2023.micro-nano.gr/plenary-speakers/
 
Description Plenary presentation - NanoBio 2023 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Gave plenary talk at NanoBio
Year(s) Of Engagement Activity 2023
URL https://nanobioconf.com/
 
Description Plenary presentation - RSC Chemical Nanoscience and Nanotechnology Interest Group 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Gave keynote talk at national meeting
Year(s) Of Engagement Activity 2024
URL https://www.rsc.org/events/detail/76838/rsc-chemical-nanoscience-and-nanotechnology-network-annual-s...
 
Description Public Seminar on Bioelectronic Medicine, University of Linkoping, Sweden. 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Public/other audiences
Results and Impact Public seminar on the occasion of award of honorary doctorate, reaching current members, alumni and steakholders of Linkoping University.
Year(s) Of Engagement Activity 2022
 
Description RSC EDI funding: Socioeconomic Inclusion Special Call 2023 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Levelling Up: Chemistry will support attainment- and aspiration-raising of Year 12 students from Nottingham and the surrounding area. From February to December, students engage in weekly tutorials and mentoring to support their journey to HE.
VCC received a grant of £5,000 (reported at Further funding) to support this activity.
Year(s) Of Engagement Activity 2023
 
Description Royal Society Summer Science Exhibition- 2023 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Public/other audiences
Results and Impact The Programme Grant Dialling Up Performance for on Demand Manufacturing team, consisting of researchers ( PhD student and post-docs), investigators, technical support. presented: "Personalised printing for pills: Can we print your perfect pill?" , i.e. the biopill concept to general public at the Royal Society.
Year(s) Of Engagement Activity 2023
URL https://royalsociety.org/science-events-and-lectures/2023/07/personalised-printing-for-pills/
 
Description Seminar at Strathclyde University (AGT) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Provided more awareness of 3D printing of personalised medication and better overview of implementing AI in additive manufacturing. Initiation of collaboration with University of Strathclyde on microfluidics.
Year(s) Of Engagement Activity 2023
 
Description iSmart Distinguished Lecture of the International Journal of Smart and Nano Materials 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact 17,000 people joined online for this lecture
Year(s) Of Engagement Activity 2024
URL https://mp.weixin.qq.com/s/qIJrRlQhwiP0SdAiu9vxWQ