A New Paradigm in "On Demand" Manufacture: Radiation Chemical Functionalisation During 3D Printing

Research Questions and Objectives: This project aims to develop a new approach to 3D printing of customised plastic devices, by functionalising polymers in situ using radiation grafting. The demonstration of this new manufacturing paradigm will be achieved by producing a 'showpiece' - a plain 3D printed cup which then gains a design containing multicolour University of Manchester and chemistry symbols when dipped in a specially prepared liquid containing dyes which key into specific functionalities. Our long-term vision is the point-of-use recycling abundant (and currently problematic) plastic waste. Polyethylene (PE), or polyethylene terephthalate (PET) will be transformed into new filaments with bespoke functionalisation in the print-head of an extrusion 3D printer, with functionalisation being programmable applied throughout the print, giving specific functionalisation in different regions of the printed device.
Approach: The student conducting this project will be responsible for:
(1) Designing, assembling, commissioning and exploiting the experimental setup for the dynamic radiation grafting combined with 3D printing;
(2) Developing and optimising 3D printing protocols yielding a variety of radiation-grafted copolymers (under both static and dynamic conditions);
(3) Producing a set of various coloured showpieces created by radiation grafted functionalities on the base polymer;
(4) Exploring potential uses of produced advanced functional materials in healthcare, sensor manufacture and nuclear applications.
Novel Engineering and Physical Sciences Content: The novelty and major scientific impact of the proposed research is in combination of 3D printing of thermoplastic polymers with the dynamic radiation grafting of these materials to afford their task-specific functionalisation; importantly, both processes can be automated and synchronised thus ensuring high manufacturing throughput and versatility. This project is well placed within the remit of the "Manufacturing the Future" theme.