SEE MORE MAKE MORE: Secondary Electron Energy Measurement Optimisation for Reliable Manufacturing of Key Materials
Lead Research Organisation:
University of Sheffield
Department Name: Materials Science and Engineering
Abstract
Additive manufacturing (AM), or 3D printing, is an exciting new form of industrial production that promises to revolutionise sectors as diverse as healthcare, energy, aerospace, and transport. By allowing stronger, lighter, and more complex components to be formed from a variety of materials, AM will play a critical role in meeting emerging technological needs over the coming decades. One area in which AM is already generating huge excitement is in bone tissue engineering for the production of implants for patients who have degenerative diseases or who need, for example, facial reconstruction following an accident or cancer. However, making large and load-bearing implants reproducibly is still a significant challenge. AM theoretically allows the reproduction of extremely complex geometries while also accounting for variation in the structural, mechanical, and cellular properties of bone tissue. Such flexibility will be essential to produce load-bearing 3D printed bones that have the strength to replace metal-based implants but which also mimic intricate vascular networks.
Much of the flexibility of AM arises from its use of composites which combine the desirable properties of several different materials. Increasingly, in a form of AM that uses a laser to continually melt (sinter) the composite material, polymers are mixed with nano-carbon to make materials stronger and more conductive. However, an outstanding challenge in the field is to ensure that the carbon is evenly distributed throughout the matrix polymer to produce printed components with reliable properties. We also need to be able to monitor nanocarbon distribution in real time during AM which will require new, innovative methods of advanced metrology.
Using the unique facilities and experience of our team, we will address these engineering challenges to provide the AM community with a step-change in their ability to produce bespoke high-quality components. To do this, we will build on significant breakthroughs we have recently made in developing new methods of hyperspectral imaging, that is, techniques that allow us to map the chemical and structural properties of a material and how these change under different conditions. Using electrons as a probe provides information on how nanocarbon particles interact with each other and their environment, for example, when heated with a laser. Such information is critical to optimise AM processes but, because this technique operates at the nanometer level, it is not practical for monitoring whole components whilst they are printed. For this, we will use another method of hyperspectral imaging based on thermal emission, similar to how we can measure temperature from the familiar glow emitted by hot coal in a fire. By combining these methods of electron imaging and thermal emission detection, we will be able to control how nanocarbon is distributed throughout a composite material and how this affects critical macroscale properties such as porosity, conductivity, strength, and surface finish. Together, this new hyperspectral imaging framework will benefit researchers and industry using AM for various applications leading to gains in cost, yield, energy efficiency, and lifetime.
Once our framework is established, we will demonstrate its effectiveness by applying it to AM of bone tissue scaffolds from a novel composite we will develop containing nanocarbon mixed with a biocompatible polymer. By optimizing the laser heating process and controlling nanocarbon distribution and state, we will make scaffolds that are fit for clinical use, as validated through tests with our industry partner Lucideon. Other partners include NPL, ASTeC, YPS, Spintex, and FBK who will enhance the impact of our project through applications in Li ion batteries, pharmaceuticals, energy materials, and accelerator technologies.
Much of the flexibility of AM arises from its use of composites which combine the desirable properties of several different materials. Increasingly, in a form of AM that uses a laser to continually melt (sinter) the composite material, polymers are mixed with nano-carbon to make materials stronger and more conductive. However, an outstanding challenge in the field is to ensure that the carbon is evenly distributed throughout the matrix polymer to produce printed components with reliable properties. We also need to be able to monitor nanocarbon distribution in real time during AM which will require new, innovative methods of advanced metrology.
Using the unique facilities and experience of our team, we will address these engineering challenges to provide the AM community with a step-change in their ability to produce bespoke high-quality components. To do this, we will build on significant breakthroughs we have recently made in developing new methods of hyperspectral imaging, that is, techniques that allow us to map the chemical and structural properties of a material and how these change under different conditions. Using electrons as a probe provides information on how nanocarbon particles interact with each other and their environment, for example, when heated with a laser. Such information is critical to optimise AM processes but, because this technique operates at the nanometer level, it is not practical for monitoring whole components whilst they are printed. For this, we will use another method of hyperspectral imaging based on thermal emission, similar to how we can measure temperature from the familiar glow emitted by hot coal in a fire. By combining these methods of electron imaging and thermal emission detection, we will be able to control how nanocarbon is distributed throughout a composite material and how this affects critical macroscale properties such as porosity, conductivity, strength, and surface finish. Together, this new hyperspectral imaging framework will benefit researchers and industry using AM for various applications leading to gains in cost, yield, energy efficiency, and lifetime.
Once our framework is established, we will demonstrate its effectiveness by applying it to AM of bone tissue scaffolds from a novel composite we will develop containing nanocarbon mixed with a biocompatible polymer. By optimizing the laser heating process and controlling nanocarbon distribution and state, we will make scaffolds that are fit for clinical use, as validated through tests with our industry partner Lucideon. Other partners include NPL, ASTeC, YPS, Spintex, and FBK who will enhance the impact of our project through applications in Li ion batteries, pharmaceuticals, energy materials, and accelerator technologies.
Organisations
- University of Sheffield (Lead Research Organisation)
- LOUGHBOROUGH UNIVERSITY (Collaboration)
- DIAMOND LIGHT SOURCE (Collaboration)
- University of Salerno (Collaboration)
- Cracow University of Technology (Collaboration)
- Witten/Herdecke University (UWH) (Collaboration)
- UNIVERSITY OF OXFORD (Collaboration)
- UNIVERSITY OF LEEDS (Collaboration)
- UNIVERSITY OF YORK (Collaboration)
- University of Queensland (Collaboration)
- UNIVERSITY OF LIVERPOOL (Collaboration)
- Science and Technology Facilities Council (Project Partner)
- Fondazione Bruno Kessler (Project Partner)
- National Physical Laboratory (Project Partner)
- Lucideon (United Kingdom) (Project Partner)
- Spintex Engineering Ltd (Project Partner)
- York Probe Sources Ltd (Project Partner)
Publications
Davies M
(2022)
Image Correction and In Situ Spectral Calibration for Low-Cost, Smartphone Hyperspectral Imaging
in Remote Sensing
Davies M
(2022)
Aerosol jet printing polymer dispersed liquid crystals on highly curved optical surfaces and edges.
in Scientific reports
Farr NTH
(2022)
Revealing Localised Mechanochemistry of Biomaterials Using In Situ Multiscale Chemical Analysis.
in Materials (Basel, Switzerland)
Nohl JF
(2022)
Low-voltage SEM of air-sensitive powders: From sample preparation to micro/nano analysis with secondary electron hyperspectral imaging.
in Micron (Oxford, England : 1993)
Gregory D
(2023)
Additive Manufacturing of Polyhydroxyalkanoate-Based Blends Using Fused Deposition Modelling for the Development of Biomedical Devices
in Journal of Functional Biomaterials
Farr N
(2023)
Regulating the formation and extent of crazing through the application of argon plasma surface functionalisation
in Polymer Testing
Farr N
(2023)
Characterization and quantification of oxidative stress induced particle debris from polypropylene surgical mesh
in Nano Select
Raut MP
(2023)
Bacterial Cellulose-Based Blends and Composites: Versatile Biomaterials for Tissue Engineering Applications.
in International journal of molecular sciences
Description | Communication with Patient Safety Commissioner |
Geographic Reach | National |
Policy Influence Type | Influenced training of practitioners or researchers |
Description | MRC Confidence in Concept Project - Reducing risks and accelerating development of biomaterials for use in the pelvic floor by introducing a new surface imaging technique |
Amount | £31,833 (GBP) |
Organisation | University of Sheffield |
Sector | Academic/University |
Country | United Kingdom |
Start | 06/2022 |
End | 03/2023 |
Description | Planned work on investigations in to the laser marking of surgical instruments and medical device materials using modern laser technologies |
Amount | £5,000 (GBP) |
Organisation | European Union |
Sector | Public |
Country | European Union (EU) |
Start | 02/2023 |
End | 03/2023 |
Description | Ptycho-tomography for composite 3D printing |
Amount | £70,000 (GBP) |
Organisation | Diamond Light Source |
Sector | Private |
Country | United Kingdom |
Start | 05/2021 |
End | 05/2021 |
Description | Ptycho-tomography for composite 3D printing for Tissue Engineering |
Amount | £70,000 (GBP) |
Organisation | Diamond Light Source |
Sector | Private |
Country | United Kingdom |
Start | 12/2022 |
End | 12/2022 |
Description | Sustainable manufacture of biodegradable film packaging from recalcitrant waste streams |
Amount | £758,964 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 06/2023 |
End | 05/2026 |
Description | X-ray tomography for 3D bioprinting |
Amount | £40,000 (GBP) |
Organisation | Diamond Light Source |
Sector | Private |
Country | United Kingdom |
Start | 04/2023 |
End | 04/2023 |
Title | Data for 'Low-voltage SEM of air-sensitive powders: From sample preparation to micro/nano analysis with secondary electron hyperspectral imaging' |
Description | SEHI data volumes included in 10.1016/j.micron.2022.103234.For methodology of preparation, collection and data processing see section 5 of the published article.Corresponding SEHI data volume metadata in .json format. |
Type Of Material | Database/Collection of data |
Year Produced | 2022 |
Provided To Others? | Yes |
Impact | This dataset contains first hyperspectral secondary electron data collected from powders and can help other researchers to identify surface functional groups that are present on individual powder particles but remain hidden from many traditional characterisation methods. The datasets have been downloaded over 800 times. |
URL | https://figshare.shef.ac.uk/articles/dataset/Data_for_Low-voltage_SEM_of_air-sensitive_powders_From_... |
Description | Cracow University of Technology - Carbon Black investigations |
Organisation | Cracow University of Technology |
Country | Poland |
Sector | Academic/University |
PI Contribution | Sharing of sample materials. Sharing of analysis equipment. Joint publication submitted. |
Collaborator Contribution | Sharing of analysis equipment. Joint publication submitted. |
Impact | Submitted publication |
Start Year | 2022 |
Description | Department of Chemistry and Biology, University of Salerno: Surface functionalisation of carbon black |
Organisation | University of Salerno |
Country | Italy |
Sector | Academic/University |
PI Contribution | Analysis of materials |
Collaborator Contribution | Provided carbon black materials |
Impact | Paper submitted. |
Start Year | 2023 |
Description | Department of Obstetrics and Gynecology Rheinlandclinics Dormagen, University of Witten Herdecke: Titanium-coated polypropylene surgical mesh explanted from humans |
Organisation | Witten/Herdecke University (UWH) |
Country | Germany |
Sector | Academic/University |
PI Contribution | Analysis of Explanted mesh |
Collaborator Contribution | Sharing of explanted materials |
Impact | https://onlinelibrary.wiley.com/doi/10.1002/jbm.b.35221 |
Start Year | 2022 |
Description | Diamond Lightsource |
Organisation | Diamond Light Source |
Country | United Kingdom |
Sector | Private |
PI Contribution | expertise, intellectual input and materials to demonstrably push boundaries of equipment on I-13-1 |
Collaborator Contribution | expertise, intellectual input and help with data analysis |
Impact | multiple joint paper drafts in preparation |
Start Year | 2021 |
Description | Loughborough University (SM3) |
Organisation | Loughborough University |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Sharing of samples and technical assistance through the training of SEHI. |
Collaborator Contribution | Equipment access to upload SEHI protocols. Technical assistance through the application of SEHI |
Impact | Paper currently in drafting |
Start Year | 2021 |
Description | Queensland Alliance for Environmental Health Sciences (QAEHS), The University of Queensland: Quantification of oxidative stress induced particle debris from polypropylene surgical mesh |
Organisation | University of Queensland |
Department | Queensland Alliance for Environmental Health Sciences |
Country | Australia |
Sector | Academic/University |
PI Contribution | Analysis of Materials. Supply of materials. |
Collaborator Contribution | Analysis of materials. |
Impact | Publication under review @ nanoselect |
Start Year | 2022 |
Description | University of Leeds (SM3) |
Organisation | University of Leeds |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Sharing of samples and technical assistance through the training of SEHI. |
Collaborator Contribution | Equipment access to upload SEHI protocols. Technical assistance through the application of SEHI and training for cryo-SEM |
Impact | Paper currently undergoing drafting |
Start Year | 2021 |
Description | University of Liverpool |
Organisation | University of Liverpool |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | data, intellectual input on data processing/ analysis |
Collaborator Contribution | intellectual input on material |
Impact | information added to database |
Start Year | 2023 |
Description | University of Oxford |
Organisation | University of Oxford |
Department | Department of Materials |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | expertise, intellectual input or the training of staff |
Collaborator Contribution | access to data, equipment or facilities |
Impact | Paper: Low-voltage SEM of air-sensitive powders: from sample preparation to micro/nano analysis with Secondary Electron Hyperspectral Imaging DOI: 10.1016/j.micron.2022.103234 |
Start Year | 2021 |
Description | University of York (SM3) |
Organisation | University of York |
Department | Department of Physics |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Sharing of samples and technical assistance through the training of SEHI. |
Collaborator Contribution | Technical assistance through the development of novel SE electron detectors. Providing access to XPS system. |
Impact | Paper currently undergoing drafting |
Start Year | 2021 |
Description | Consulting on BBC Documentary |
Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Media (as a channel to the public) |
Results and Impact | Consulting on a BBC documentary presented by Jim Al Khalili and directed by Tim Usbourne on the origins and advancement of electron microscopy. |
Year(s) Of Engagement Activity | 2022 |
Description | Consulting on Channel 4/ BBC Asia/ SBS Documentary |
Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Media (as a channel to the public) |
Results and Impact | Consulting on the Channel 4/ BBC Asia/ SBS Documentary "Engineering Reborn" presented by Passion Distribution. |
Year(s) Of Engagement Activity | 2022,2023 |
URL | https://www.sbs.com.au/ondemand/zh-hant/tv-series/engineering-reborn |
Description | Interactions with House of Lords and House of Commons |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Policymakers/politicians |
Results and Impact | I am currently in correspondence with Lady Cumberlege (Member of the House of Lords) and two MPs to support an application for the Royal Society MP/Researcher pairing scheme - https://royalsociety.org/grants-schemes-awards/pairing-scheme/. Lady Cumberlege shares my ideals of the importance of public engagement with science and will be a fantastic partner for this application. Lady Cumberlege and two MPs have shared my research on their social media accounts. |
Year(s) Of Engagement Activity | 2022 |
Description | Offer holder days |
Form Of Engagement Activity | Participation in an open day or visit at my research institution |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Public/other audiences |
Results and Impact | Offer holder to Materials Science & Engineering Undergraduate courses are invited to the University to tour some of the research and teaching facilities and to learn about ongoing research activities to support their decision making. |
Year(s) Of Engagement Activity | 2023 |
Description | On campus open day |
Form Of Engagement Activity | Participation in an open day or visit at my research institution |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Public/other audiences |
Results and Impact | Explained Materials Science & Engineering to potential applicants and parents |
Year(s) Of Engagement Activity | 2022 |
Description | Participation in 2nd UK Advanced Materials Workshop |
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 | This workshop looked potential barriers to the adoption and upscaling of some types of advanced materials. I contributed to the discussion during breakout sessions. |
Year(s) Of Engagement Activity | 2023 |
Description | Research talk and Q&A panel member to 2D materials CDT conference 2022 |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Professional Practitioners |
Results and Impact | I gave a research talk - informing PGR cohorts of 2D materials CDT on research on SEE MORE MAKE MORE and how this relates to energy and 2 D Materials. I was a member of a Q&A panel (representing Academia). I was joined by a panel member representing SME and knowledge transfer unit respectively. The panel answered questions on future career path, IP etc. and spin outs etc. This helped students to plan for and decide on future career path after PhD. |
Year(s) Of Engagement Activity | 2022 |
Description | online Taster day for secondary schools |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Schools |
Results and Impact | A talk to introduce Materials Science & Engineering to Y12 pupils to increase awareness of this subject area. |
Year(s) Of Engagement Activity | 2022 |