Current and future trends of additive manufacturing for chemistry applications: a review

Freeform generative design of complex functional structures

Generative machine learning is poised to revolutionise a range of domains where rational design has long been the de facto approach: where design is practically a time consuming and frustrating process guided by heuristics and intuition. In this article we focus on the domain of flow chemistry, which is an ideal candidate for generative design approaches. We demonstrate a generative machine learning framework that optimises diverse, bespoke reactor elements for flow chemistry applications, combining evolutionary algorithms and a scalable fluid dynamics solver for in silico performance assessment. Experimental verification confirms the discovery of never-before-seen bespoke mixers whose performance exceeds the state of the art by 45%. These findings highlight the power of autonomous generative design to improve the operational performance of complex functional structures, with potential wide-ranging industrial applications.

The Evolution of Technology-Driven In Vitro Models for Neurodegenerative Diseases

The alteration in the neural circuits of both central and peripheral nervous systems is closely related to the onset of neurodegenerative disorders (NDDs). Despite significant research efforts, the knowledge regarding NDD pathological processes, and the development of efficacious drugs are still limited due to the inability to access and reproduce the components of the nervous system and its intricate microenvironment. 2D culture systems are too simplistic to accurately represent the more complex and dynamic situation of cells in vivo and have therefore been surpassed by 3D systems. However, both models suffer from various limitations that can be overcome by employing two innovative technologies: organ-on-chip and 3D printing. In this review, an overview of the advantages and shortcomings of both microfluidic platforms and extracellular matrix-like biomaterials will be given. Then, the combination of microfluidics and hydrogels as a new synergistic approach to study neural disorders by analyzing the latest advances in 3D brain-on-chip for neurodegenerative research will be explored.

The contemporary nexus of medicines security and bioprospecting: a future perspective for prioritizing the patient

Reacting to the challenges presented by the evolving nexus of environmental change, defossilization, and diversified natural product bioprospecting is vitally important for advancing global healthcare and placing patient benefit as the most important consideration. This overview emphasizes the importance of natural and synthetic medicines security and proposes areas for global research action to enhance the quality, safety, and effectiveness of sustainable natural medicines. Following a discussion of some contemporary factors influencing natural products, a rethinking of the paradigms in natural products research is presented in the interwoven contexts of the Fourth and Fifth Industrial Revolutions and based on the optimization of the valuable assets of Earth. Following COP28, bioprospecting is necessary to seek new classes of bioactive metabolites and enzymes for chemoenzymatic synthesis. Focus is placed on those performance and practice modifications which, in a sustainable manner, establish the patient, and the maintenance of their prophylactic and treatment needs, as the priority. Forty initiatives for natural products in healthcare are offered for the patient and the practitioner promoting global action to address issues of sustainability, environmental change, defossilization, quality control, product consistency, and neglected diseases to assure that quality natural medicinal agents will be accessible for future generations.

3D printed graphite-based electrode coupled with batch injection analysis: An affordable high-throughput strategy for atorvastatin determination

This work integrated a lab-made conductive graphite/polylactic acid (Grp/PLA, 40:60% w/w) filament into a 3D pen to print customized electrodes (cylindrical design). Thermogravimetric analysis validated the incorporation of graphite into the PLA matrix, while Raman spectroscopy and scanning electron microscopy images indicated a graphitic structure with the presence of defects and highly porous, respectively. The electrochemical features of the 3D-printed Gpt/PLA electrode were systematically compared to that achieved using commercial carbon black/polylactic acid (CB/PLA, from Protopasta®) filament. The 3D printed Gpt/PLA electrode "in the native form" provided lower charge transfer resistance (Rct = 880 Ω) and a more kinetically favored reaction (K⁰ = 1.48 × 10^-3 cm s^-1) compared to the 3D printed CB/PLA electrode (chemically/electrochemically treated). Moreover, a method by batch injection analysis with amperometric detection (BIA-AD) was developed to determine atorvastatin (ATR) in pharmaceutical and water samples. Using the 3D printed Gpt/PLA electrode, a wider linear range (1-200 μmol L^-1), sensitivity (3-times higher), and lower detection limit (LOD = 0.13 μmol L^-1) were achieved when compared to the CB/PLA electrode. Repeatability studies (n = 15, RSD <7.3%) attested to the precision of the electrochemical measurements, and recovery percentages between 83 and 108% confirmed the accuracy of the method. Remarkably, this is the first time that ATR has been determined by the BIA-AD system and a low-cost 3D-printed device. This approach is promising to be implemented in research laboratories for quality control of pharmaceuticals and can also be useful for on-site environmental analysis.

FOMSy: 3D-printed flexible open-source microfluidic system and flow synthesis of PET-tracer

In this work, we introduce a low-cost open-source flow system that includes a dual syringe pump with implemented pressure sensor and back pressure regulator. The entire system can be built for around 500 €. Commercially available flow systems can be very expensive with equipment starting at, but often greatly exceeding, 10,000 €. This high price of entry makes such technology prohibitively expensive for many research groups. Such systems stand to benefit the emerging academic pharmaceutical field by providing the experience and availability of reliable and affordable solutions. To implement accessible flow chemistry at research facilities, the systems must be made affordable. In addition, space in research laboratories is usually limited and commercially available flow systems can be very bulky. Having a compact and individually adjustable system is thus beneficial, with 3D printing technology offering the solution. Our compact 3D-printed system meets the needs of many applications in flow chemistry research as well as educational requirements for universities. As a proof of concept, we conceptualized, developed, and tested a custom flow system that can be used to synthesize [18F]2-fluoro-2-desoxy-d-glucose ([18F]FDG), the most commonly used PET-tracer. This system was designed to perform the typical functions and operations required in radiotracer production i.e. radiofluorination, dilution, SPE-trapping, deprotection, and SPE-elution. With this proof-of-concept in hand, the system can be easily customized to produce other radiopharmaceuticals.

Additively manufactured polyether ether ketone (PEEK) skull implant as an alternative to titanium mesh in cranioplasty

173Cranioplasty is used for skull defects, involving lifting the scalp and restoring the contour of the skull with the original skull piece, titanium mesh, or solid biomaterial. Additive manufacturing (AM) technology, known as three-dimensional (3D) printing, is now utilized by medical professionals to develop customized replicas of tissues, organs and bones, offering a valid option with perfect anatomic fitting in the individual and skeletal reconstruction. Here, we report a case that underwent titanium mesh cranioplasty 15 years ago. The poor appearance of the titanium mesh weakened the left eyebrow arch and resulted in the formation of a sinus tract. Cranioplasty was performed using an additively manufactured polyether ether ketone (PEEK) skull implant. PEEK skull implants have been successfully implanted without any complications. To our knowledge, this is the first reported case of direct use of fused filament fabrication (FFF)-fabricated PEEK implant for cranial repair. The FFF-printed PEEK customized skull implant could possess simultaneously with adjustable material thickness and more complex structure, tunable mechanical properties, and low processing costs compared with traditional manufacturing processes. While meeting clinical needs, this production method is an appropriate alternative for promoting the use of PEEK materials in cranioplasty.

Process Intensification in a Double-Pipe Reactor with Additively Manufactured Internal Inserts

The polycondensation reaction to produce polydextrose can be intensified by using micro-process engineering. Fluid Guiding Elements are additively manufactured internal inserts that have already shown their potential to intensify heat transfer in double-pipe heat exchangers. This study investigated the intensification of the polydextrose yield when these internal inserts were used. Different reactor lengths and internal inserts geometries, as well as different operating conditions, were analyzed. The experiments showed that the reactant concentration had no effect on the product yield. Furthermore, it was shown that the process could be intensified at higher temperatures, with relatively low residence times and lower pressures. It was confirmed that the good heat transfer characteristics of the internal inserts allow them to continuously evaporate water during the reaction and to further reach the required reaction temperature, thus shifting the equilibrium towards the desired product. These findings are of special significance for the optimization of the polycondensation reaction of polydextrose.

High-Resolution 3D Printing Fabrication of a Microfluidic Platform for Blood Plasma Separation

Additive manufacturing technology is an emerging method for rapid prototyping, which enables the creation of complex geometries by one-step fabrication processes through a layer-by-layer approach. The simplified fabrication achieved with this methodology opens the way towards a more efficient industrial production, with applications in a great number of fields such as biomedical devices. In biomedicine, blood is the gold-standard biofluid for clinical analysis. However, blood cells generate analytical interferences in many test procedures; hence, it is important to separate plasma from blood cells before analytical testing of blood samples. In this research, a custom-made resin formulation combined with a high-resolution 3D printing methodology were used to achieve a methodology for the fast prototype optimization of an operative plasma separation modular device. Through an iterative process, 17 different prototypes were designed and fabricated with printing times ranging from 5 to 12 min. The final device was evaluated through colorimetric analysis, validating this fabrication approach for the qualitative assessment of plasma separation from whole blood. The 3D printing method used here demonstrates the great contribution that this microfluidic technology will bring to the plasma separation biomedical devices market.

Predictive Modeling of Thermally Assisted Machining and Simulation Based on RSM after WAAM

The WAAM (Wire Arc Additive Manufacturing) process is well-respected because of its low cost and high deposition efficiency; nevertheless, the process has the limitations of high heat input and low forming accuracy. Hybrid manufacturing processes employing both additive and subtractive processes can effectively reduce shape error. The predictive modeling of surface roughness in thermally assisted machining is described in this paper on the basis of three important parameters: feed per tooth, spindle speed, and workpiece temperature. The predictive model indicates that temperature has a very significant influence on the surface quality. An experimental study on thermally assisted machining was performed to obtain the variation law of cutting surface quality with temperature in order to determine the optimal process interval of subtractive processes. Through finite element simulation of thermally assisted machining, the influence law of external main cutting force and the internal mean stress of the cutting material were determined.

Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

The aim of this work is to evaluate the performance of the stirring 3D Fe/Al2O3 monolithic reactor in batch operation applied to the liquid-phase hydroxylation of phenol by hydrogen peroxide (H2O2). An experimental and numerical investigation was carried out at the following operating conditions: CPHENOL,0 = 0.33 M, CH2O2,0 = 0.33 M, T = 75–95 °C, P = 1 atm, ω = 200–500 rpm and WCAT ~ 1.1 g. The kinetic model described the consumption of the H2O2 by a zero-order power-law equation, while the phenol hydroxylation and catechol and hydroquinone production by Eley–Rideal model; the rate determining step was the reaction between the adsorbed H2O2, phenol in solution with two active sites involved. The 3D CFD model, coupling the conservation of mass, momentum and species together with the reaction kinetic equations, was experimentally validated. It demonstrated a laminar flow characterized by the presence of an annular zone located inside and surrounding the monoliths (u = 40–80 mm s−1) and a central vortex with very low velocities (u = 3.5–8 mm s−1). The simulation study showed the increasing phenol selectivity to dihydroxybenzenes by the reaction temperature, while the initial H2O2 concentration mainly affects the phenol conversion.