Biorelevant Multi- Material Additive Manufacturing at Nottingham. Ricky Wildman. Faculty of Engineering and School of Pharmacy
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1 Biorelevant Multi- Material Additive Manufacturing at Nottingham Ricky Wildman Faculty of Engineering and School of Pharmacy
2 Contents 3D Printing at Nottingham: EPSRC Centre for Innovative Manufacturing in Additive Manufacturing Ink jet printing Opportunities in healthcare Nano scale
3 Contents 3D printing at University of Nottingham Why 3D printing? Complexity enabled Optimal structures achievable Bespoke Customisation Multimaterial, multicomponent, multifunction in one step Embedded and graded functionality Electronics & sensors Pharmaceuticals Multicomponent devices Personalised devices
4 Staff EPSRC Centre for Additive Manufacturing Goal: To move from single material, single function, to multifunctional industrially relevant 3D printing Over 40 staff and Post- Grads dedicated to AM research Collaboration with Laboratory of Biophysics and Surface Analysis
5 Goal: Multifunctional printing Aim: To create multifunctional devices & components in a single manufacturing step Produced for the Science Museum exhibition 3D: printing the future
6 Contents 3D Printing at Nottingham: EPSRC Centre for Innovative Manufacturing in Additive Manufacturing Ink jet printing Opportunities in healthcare Nano scale
7 Ink jet printing: Reactive Jetting Ink jet printing: most promising method for multimaterial manufacturing Limited capability when printing off the shelf materials Concept of printing structural materials Two different inks i.e. monomer and catalyst Two-part systems activator and monomer UV curable Requires process and chemistry considerations to be made in tandem Kinetics Diffusion mechanism Viscosity Surface Tension
8 Curing polymers in situ Simultaneous curing and sintering mechanisms Power socket Heating element (reached 180 C) Ceramic thermal insulator
9 Example End Goal - Incorporated electronics and printed interconnect Current Aim: Incorporating electronic components and inkjet printed conductive tracks inside 3D printed structures Printed interconnecting tracks embedded Rechargeable battery Resistor LED Switch
10 Major Challenges Material Ink conductivity Dielectric ink stability Thermal / Chemical / Structural Ink drying Height Mismatch System Multiple BMP More than two materials Curing Mechanism Sintering Temperatures Print head control cooling!
11 Enabling Complex products Multifunctional, multimaterial products Graded products Resolution < 50mm
12 Contents 3D Printing at Nottingham: EPSRC Centre for Innovative Manufacturing in Additive Manufacturing Ink jet printing Opportunities in healthcare Nano scale
13 2D array printing: a novel concept for oral dosage form manufacture
14 3D Printing: Extrusion of solid dosage forms Extrusion based 3D printer setup for dual material deposition
15 Going further: Printed bilayer structures
16 Getting better control: Ink jet printing bioresorbable materials Development of PCL(DA) as a UV curable bioresorbable ink (polycaprolactone macromer with diacrylate functional groups at the ends for UV driven cross-linking) Cured using UV illumination Initiators include Type 1: Irgacure 2959 Type 2: Photoinitiator: 2,4- Diethyl-9H-thioxanthen-9- one Accelerator: Ethyl 4- (dimethylamino)benzoate 4mm 10 Layers UV cured PCLDA-PEGDA ink (PCLDA:PEGDA=60%:40%, Droplet Spacing=40μm, Thickness=55 μm)
17 Demonstrating complexity
18 Ink jet printing enabling multifunctional Multifunctional means Structural, sensing, actuation for biomedical devices Structural, active pharma ingredient for drug delivery systems
19 Contents 3D Printing at Nottingham: EPSRC Centre for Innovative Manufacturing in Additive Manufacturing Ink jet printing Opportunities in healthcare Nano scale
20 System Design Based on Multi photon microscopy system
21 Multi-photon polymerisation system Material: OrmoComp Laser: Coherent Chameleon Ultra II, 780 nm, 80 MHz, 48 mw 100x oil-immersion lens, scanning speed 10 µm/s Before developing Video: Scan a Video: Scan b After developing 10 µm 250 µm 27 layers 500 nm/layer
22 Why NANOS? Smart micropatterned neural interfaces Collaboration with Electrical Engineering and Biology The aim is to fabricate a sensor platform to investigate neural information processing Neural Interface: Allows for bidirectional communication between neural tissue and a computer. In vitro: in glass, outside the body Goal: Build a platform for investigating the information processing of neural networks.
23 Enhancing MPP with Optical Trapping Aim to manufacture double negative meta-materials using multi-photon polymerisation and optical trapping (OT) Manufacture of structures with different physical and electro-magnetic properties combining MPP and OT Fabrication of meta-material structures within a wider electromagnetic frequency range (into the visible) Combination of optical trapping techniques with MPP rig to produce a system capable of manoeuvring active elements within a structure Initiated with a single, low power, OT system
24 Nano scale 3D Printing Structures with feature sizes <100nm Multimaterial devices on the nano scale Hybridisation means integration of length scales (e.g., with optical tweezers) Sensors (bio, opto)
25 Recent Award Great Technologies EPSRC Equipment Call Successful in obtaining 2.7Million for Equipment Multimaterial AM MetalJet Jetting of metallic droplets from 2000 degc with Oce JetMax 6 head jetting system with multiple material conversion routes 200mm build height NANOS+ - Multi-material 2PP system with multi-beam optical control and placement Analytical ToF SIMS upgrade (with Pharmacy) AFM upgrade (with Pharmacy)
26 Centre for Doctoral Training in AM and 3D Printing Centre for Doctoral Training Specific AM training for PhD 70 PhD students over 5 years Four partners, Liverpool, Newcastle and Loughborough Bespoke training programme for basic AM training prior to PhD work Industry-base utilised for directing teaching activities Internships in companies Professional Environment Study Tours Industry partners providing 30-45k per student for enhanced stipend/travel and consumables October 2014 start date
27 Acknowledgements Big thanks to: Chris Tuck Bochuan Liu Ehab Saleh Yinfeng He Clive Roberts Morgan Alexander Sam Kilsby (Lboro) Steve Christie (Lboro) Steve Edmondson (Lboro) Mark East Mark Hardy Richard Hague Ian Ashcroft Marcel Slot (Oce) Qin Hu Meisam Askari Astra-Zeneca
28 Any Questions? Any Questions? Prof. Ricky Wildman e: w: w:
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