Surviving function during fluid-based advanced manufacturing

Roll-to-roll processing and inkjet printing are being explored as advanced manufacturing approaches for biomaterials, cells, pharmaceutical manufacturing, combinatorial chemistry, high-throughput screening and biosensor fabrication. However, the fluid-based processing imparts a complex range of forces (pressure, multiple rates of shear, elongation, etc.) on these delicate materials from the mixing in a storage reservoir to surface deposition that depends on both formulation and manufacturing parameters. The effects can be drastic, including changes in biological activity, drug crystallinity, polymorphism and sensor functionality. The state of the art was explored for inkjet printing with pharmaceuticals [Daly et al. (2015) Int. J. Pharm.]and a clear opportunity for urgently needed work was identified. The aims are therefore: 1. To clearly identify through the initial literature review a set of model systems that represent the different challenges faced in these fluid-based processes (e.g. (i) long-chain molecules with complex secondary and tertiary structures, (ii) large colloid-like particles with essential external functional groups, (iii) small molecule drugs, (iv) functionalised rigid nanomaterials). 2. Examine the underlying forces at work at each stage of the advanced manufacturing processes (roll-to-roll and inkjet printing) by finding (i) methods of examining in isolation through new experiments and (ii) examining in-situ in a highly controlled and monitored equivalent to the target manufacturing system. 3. Leverage unique facilities already in place to examine the control over molecule functionality using distinct scalable and translatable manufacturing technologies. (e.g. (i) highly controlled single-nozzle inkjet printing with high speed imaging, (ii) 16-nozzle inkjet printing often used for industrial research, (iii) industrial scale printheads used for high throughput manufacturing. This will link with the current departmental theme of Bioengineering through identifying the underpinning science of manufacturing with biologically active materials. Also, this will link with the Manufacturing the Future theme in EPSRC by enabling specific design of novel materials for advanced manufacturing approaches.