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Kalinke C, Crapnell RD, de Oliveira PR, Janegitz BC, Bonacin JA, Banks CE. How to Improve Sustainability in Fused Filament Fabrication (3D Printing) Research? GLOBAL CHALLENGES (HOBOKEN, NJ) 2024; 8:2300408. [PMID: 39006060 PMCID: PMC11237179 DOI: 10.1002/gch2.202300408] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/29/2023] [Revised: 04/11/2024] [Indexed: 07/16/2024]
Abstract
This review aims to provide an overview of sustainable approaches that can be incorporated into well-known procedures for the development of materials, pre- and post-treatments, modifications, and applications of 3D-printed objects, especially for fused filament fabrication (FFF). Different examples of conductive and non-conductive bespoke filaments using renewable biopolymers, bioplasticizers, and recycled materials are presented and discussed. The main final characteristics of the polymeric materials achieved according to the feedstock, preparation, extrusion, and treatments are also covered. In addition to recycling and remanufacturing, this review also explores other alternative approaches that can be adopted to enhance the sustainability of methods, aiming to produce efficient and environmentally friendly 3D printed products. Adjusting printing parameters and miniaturizing systems are also highlighted in this regard. All these recommended strategies are employed to minimize environmental damage, while also enabling the production of high-quality, economical materials and 3D printed systems. These efforts align with the principles of Green Chemistry, Sustainable Development Goals (SDGs), 3Rs (Reduce, Reuse, Recycle), and Circular Economy concepts.
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Affiliation(s)
- Cristiane Kalinke
- Institute of ChemistryUniversity of Campinas (UNICAMP)CampinasSão Paulo13083–859Brazil
- Faculty of Science and EngineeringManchester Metropolitan UniversityChester StreetManchesterM1 5GDUK
| | - Robert D. Crapnell
- Faculty of Science and EngineeringManchester Metropolitan UniversityChester StreetManchesterM1 5GDUK
| | - Paulo R. de Oliveira
- Faculty of Science and EngineeringManchester Metropolitan UniversityChester StreetManchesterM1 5GDUK
- Department of Nature SciencesMathematics, and EducationFederal University of São Carlos (UFSCar)ArarasSão Paulo13600–970Brazil
| | - Bruno C. Janegitz
- Department of Nature SciencesMathematics, and EducationFederal University of São Carlos (UFSCar)ArarasSão Paulo13600–970Brazil
| | - Juliano A. Bonacin
- Institute of ChemistryUniversity of Campinas (UNICAMP)CampinasSão Paulo13083–859Brazil
| | - Craig E. Banks
- Faculty of Science and EngineeringManchester Metropolitan UniversityChester StreetManchesterM1 5GDUK
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2
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Augusto KKL, Crapnell RD, Bernalte E, Zighed S, Ehamparanathan A, Pimlott JL, Andrews HG, Whittingham MJ, Rowley-Neale SJ, Fatibello-Filho O, Banks CE. Optimised graphite/carbon black loading of recycled PLA for the production of low-cost conductive filament and its application to the detection of β-estradiol in environmental samples. Mikrochim Acta 2024; 191:375. [PMID: 38849611 PMCID: PMC11161437 DOI: 10.1007/s00604-024-06445-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2024] [Accepted: 05/22/2024] [Indexed: 06/09/2024]
Abstract
The production, optimisation, physicochemical, and electroanalytical characterisation of a low-cost electrically conductive additive manufacturing filament made with recycled poly(lactic acid) (rPLA), castor oil, carbon black, and graphite (CB-G/PLA) is reported. Through optimising the carbon black and graphite loading, the best ratio for conductivity, low material cost, and printability was found to be 60% carbon black to 40% graphite. The maximum composition within the rPLA with 10 wt% castor oil was found to be an overall nanocarbon loading of 35 wt% which produced a price of less than £0.01 per electrode whilst still offering excellent low-temperature flexibility and reproducible printing. The additive manufactured electrodes produced from this filament offered excellent electrochemical performance, with a heterogeneous electron (charge) transfer rate constant, k0 calculated to be (2.6 ± 0.1) × 10-3 cm s-1 compared to (0.46 ± 0.03) × 10-3 cm s-1 for the commercial PLA benchmark. The additive manufactured electrodes were applied to the determination of β-estradiol, achieving a sensitivity of 400 nA µM-1, a limit of quantification of 70 nM, and a limit of detection of 21 nM, which compared excellently to other reports in the literature. The system was then applied to the detection of ß-estradiol within four real water samples, including tap, bottled, river, and lake water, where recoveries between 95 and 109% were obtained. Due to the ability to create high-performance filament at a low material cost (£0.06 per gram) and through the use of more sustainable materials such as recycled polymers, bio-based plasticisers, and naturally occurring graphite, additive manufacturing will have a permanent place within the electroanalysis arsenal in the future.
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Affiliation(s)
- Karen K L Augusto
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
- Laboratório de Analítica, Bioanalítica, Biosensores, Electroanalítica e Sensores, Departamento de Química, Universidade Federal de São Carlos (UFSCar), Sao Carlos, CP 676, 13560-970, SP, Brazil
| | - Robert D Crapnell
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Elena Bernalte
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Sabri Zighed
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
- Department of Physical Measurements, Sorbonne Paris North University, Place du 8 Mai 1945, Saint-Denis, 93200, France
| | - Anbuchselvan Ehamparanathan
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
- Department of Physical Measurements, Sorbonne Paris North University, Place du 8 Mai 1945, Saint-Denis, 93200, France
| | - Jessica L Pimlott
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Hayley G Andrews
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Matthew J Whittingham
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Samuel J Rowley-Neale
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain
| | - Orlando Fatibello-Filho
- Laboratório de Analítica, Bioanalítica, Biosensores, Electroanalítica e Sensores, Departamento de Química, Universidade Federal de São Carlos (UFSCar), Sao Carlos, CP 676, 13560-970, SP, Brazil
| | - Craig E Banks
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, M1 5GD, Manchester, Great Britain.
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Roveda LM, Ottoni VF, de Carvalho CT, Rodrigues R, Corazza MZ, Trindade MAG. Merging 3D-printing technology and disposable materials for electrochemical purposes: A sustainable alternative to ensure greener electroanalysis. Talanta 2024; 272:125814. [PMID: 38428135 DOI: 10.1016/j.talanta.2024.125814] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/26/2023] [Revised: 02/15/2024] [Accepted: 02/18/2024] [Indexed: 03/03/2024]
Abstract
3D-printing technology has revolutionized electrochemical applications by enabling rapid prototyping of various devices with high precision, even in highly complex structures. However, a significant challenge remains in developing less costly and more sustainable analytical approaches and methods aimed at mitigating the negative environmental impacts of chemical analysis procedures. In this study, we propose a solution to these challenges by creating a simple and versatile electrochemical system that combines 3D-printing technology with recyclable disposable materials, such as graphite from an exhausted battery and a stainless-steel screw. Our results demonstrate a novel strategy for developing electrodes and other laboratory-made devices that align with the principles of sustainability and green chemistry. Furthermore, we provide evidence of the effectiveness of the proposed system in an analytical application involving the simultaneous determination of tert-butylhydroquinone, acetaminophen, and levofloxacin using the voltammetric technique in lake and groundwater samples. The results indicate sufficient accuracy, with recovery values ranging from 91 to 110%. Additionally, we utilized the Analytical GREEnness calculator as a metric system to evaluate the environmental friendliness of the proposed electroanalytical protocol. The final score confirms a favorable level of sustainability, reaffirming the eco-friendly nature of our approach.
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Affiliation(s)
- Liriana Mara Roveda
- Universidade Federal da Grande Dourados, Rodovia Dourados-Itahum, km 12, Dourados, MS, CEP, 79804-970, Brazil
| | - Vitor Ferreira Ottoni
- Universidade Federal da Grande Dourados, Rodovia Dourados-Itahum, km 12, Dourados, MS, CEP, 79804-970, Brazil
| | - Cláudio Teodoro de Carvalho
- Universidade Federal da Grande Dourados, Rodovia Dourados-Itahum, km 12, Dourados, MS, CEP, 79804-970, Brazil
| | - Raphael Rodrigues
- Universidade Federal da Grande Dourados, Rodovia Dourados-Itahum, km 12, Dourados, MS, CEP, 79804-970, Brazil
| | - Marcela Zanetti Corazza
- Universidade Estadual de Londrina, Departamento de Química, Londrina, PR, CEP, 86057-970, Brazil.
| | - Magno Aparecido Gonçalves Trindade
- Universidade Federal da Grande Dourados, Rodovia Dourados-Itahum, km 12, Dourados, MS, CEP, 79804-970, Brazil; Unesp, National Institute for Alternative Technologies of Detection, Toxicological Evaluation and Removal of Micropollutants and Radioactives (INCT-DATREM), Institute of Chemistry, P.O. Box 355, Araraquara, SP, CEP, 14800-900, Brazil.
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Crapnell RD, Banks CE. Electroanalysis overview: additive manufactured biosensors using fused filament fabrication. ANALYTICAL METHODS : ADVANCING METHODS AND APPLICATIONS 2024; 16:2625-2634. [PMID: 38639065 DOI: 10.1039/d4ay00278d] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 04/20/2024]
Abstract
Additive manufacturing (3D-printing), in particular fused filament fabrication, presents a potential paradigm shift in the way electrochemical based biosensing platforms are produced, giving rise to a new generation of personalized and on-demand biosensors. The use of additive manufactured biosensors is unparalleled giving rise to unique customization, facile miniaturization, ease of use, economical but yet, still providing sensitive and selective approaches towards the target analyte. In this mini review, we focus on the use of fused filament fabrication additive manufacturing technology alongside different biosensing approaches that exclusively use antibodies, enzymes and associated biosensing materials (mediators) providing an up-to-date overview with future considerations to expand the additive manufacturing biosensors field.
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Affiliation(s)
- Robert D Crapnell
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester M1 5GD, UK.
| | - Craig E Banks
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester M1 5GD, UK.
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Crapnell RD, Bernalte E, Sigley E, Banks CE. Recycled PETg embedded with graphene, multi-walled carbon nanotubes and carbon black for high-performance conductive additive manufacturing feedstock. RSC Adv 2024; 14:8108-8115. [PMID: 38464694 PMCID: PMC10921296 DOI: 10.1039/d3ra08524d] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2023] [Accepted: 02/22/2024] [Indexed: 03/12/2024] Open
Abstract
The first report of conductive recycled polyethylene terephthalate glycol (rPETg) for additive manufacturing and electrochemical applications is reported herein. Graphene nanoplatelets (GNP), multi-walled carbon nanotubes (MWCNT) and carbon black (CB) were embedded within a recycled feedstock to produce a filament with lower resistance than commercially available conductive polylactic acid (PLA). In addition to electrical conductivity, the rPETg was able to hold >10 wt% more conductive filler without the use of a plasticiser, showed enhanced temperature stability, had a higher modulus, improved chemical resistance, lowered levels of solution ingress, and could be sterilised in ethanol. Using a mix of carbon materials CB/MWCNT/GNP (25/2.5/2.5 wt%) the electrochemical performance of the rPETg filament was significantly enhanced, providing a heterogenous electrochemical rate constant, k0, equating to 0.88 (±0.01) × 10-3 cm s-1 compared to 0.46 (±0.02) × 10-3 cm s-1 for commercial conductive PLA. This work presents a paradigm shift within the use of additive manufacturing and electrochemistry, allowing the production of electrodes with enhanced electrical, chemical and mechanical properties, whilst improving the sustainability of the production through the use of recycled feedstock.
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Affiliation(s)
- Robert D Crapnell
- Faculty of Science and Engineering, Manchester Metropolitan University Chester Street M1 5GD UK +44(0)1612471196
| | - Elena Bernalte
- Faculty of Science and Engineering, Manchester Metropolitan University Chester Street M1 5GD UK +44(0)1612471196
| | - Evelyn Sigley
- Faculty of Science and Engineering, Manchester Metropolitan University Chester Street M1 5GD UK +44(0)1612471196
| | - Craig E Banks
- Faculty of Science and Engineering, Manchester Metropolitan University Chester Street M1 5GD UK +44(0)1612471196
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Crapnell RD, Arantes IVS, Camargo JR, Bernalte E, Whittingham MJ, Janegitz BC, Paixão TRLC, Banks CE. Multi-walled carbon nanotubes/carbon black/rPLA for high-performance conductive additive manufacturing filament and the simultaneous detection of acetaminophen and phenylephrine. Mikrochim Acta 2024; 191:96. [PMID: 38225436 PMCID: PMC10789692 DOI: 10.1007/s00604-023-06175-2] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/14/2023] [Accepted: 12/26/2023] [Indexed: 01/17/2024]
Abstract
The combination of multi-walled carbon nanotubes (MWCNT) and carbon black (CB) is presented to produce a high-performance electrically conductive recycled additive manufacturing filament. The filament and subsequent additively manufactured electrodes were characterised by TGA, XPS, Raman, and SEM and showed excellent low-temperature flexibility. The MWCNT/CB filament exhibited an improved electrochemical performance compared to an identical in-house produced bespoke filament using only CB. A heterogeneous electrochemical rate constant, [Formula: see text] of 1.71 (± 0.19) × 10-3 cm s-1 was obtained, showing an almost six times improvement over the commonly used commercial conductive CB/PLA. The filament was successfully tested for the simultaneous determination of acetaminophen and phenylephrine, producing linear ranges of 5-60 and 5-200 μM, sensitivities of 0.05 μA μM-1 and 0.14 μA μM-1, and limits of detection of 0.04 μM and 0.38 μM, respectively. A print-at-home device is presented where a removable lid comprised of rPLA can be placed onto a drinking vessel and the working, counter, and reference components made from our bespoke MWCNT/CB filament. The print-at-home device was successfully used to determine both compounds within real pharmaceutical products, with recoveries between 87 and 120% over a range of three real samples. This work paves the way for fabricating new highly conductive filaments using a combination of carbon materials with different morphologies and physicochemical properties and their application to produce additively manufactured electrodes with greatly improved electrochemical performance.
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Affiliation(s)
- Robert D Crapnell
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK
| | - Iana V S Arantes
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK
- Departmento de Química Fundamental, Instituto de Química, Universidade de São Paulo, São Paulo, SP, 05508-000, Brazil
| | - Jéssica R Camargo
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK
- Laboratory of Sensors, Nanomedicine and Nanostructured Materials, Federal University of São Carlos, Araras, 13600-970, Brazil
| | - Elena Bernalte
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK
| | - Matthew J Whittingham
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK
| | - Bruno C Janegitz
- Laboratory of Sensors, Nanomedicine and Nanostructured Materials, Federal University of São Carlos, Araras, 13600-970, Brazil
| | - Thiago R L C Paixão
- Departmento de Química Fundamental, Instituto de Química, Universidade de São Paulo, São Paulo, SP, 05508-000, Brazil
| | - Craig E Banks
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester, M1 5GD, UK.
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Arantes IV, Crapnell RD, Bernalte E, Whittingham MJ, Paixão TRLC, Banks CE. Mixed Graphite/Carbon Black Recycled PLA Conductive Additive Manufacturing Filament for the Electrochemical Detection of Oxalate. Anal Chem 2023; 95:15086-15093. [PMID: 37768700 PMCID: PMC10568530 DOI: 10.1021/acs.analchem.3c03193] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/20/2023] [Accepted: 09/19/2023] [Indexed: 09/29/2023]
Abstract
Mixing of graphite and carbon black (CB) alongside recycled poly(lactic acid) and castor oil to create an electrically conductive additive manufacturing filament without the use of solvents is reported herein. The additively manufactured electrodes (AMEs) were electrochemically benchmarked against a commercial conductive filament and a bespoke filament utilizing only CB. The graphite/CB produced a heterogeneous rate constant, k0, of 1.26 (±0.23) × 10-3 cm s-1 and resistance of only 155 ± 15 Ω, compared to 0.30 (±0.03) × 10-3 cm s-1 and 768 ± 96 Ω for the commercial AME. Including graphite within the filament reduced the cost of printing each AME from £0.09, with the CB-only filament, to £0.05. The additive manufacturing filament was successfully used to create an electroanalytical sensing platform for the detection of oxalate within a linear range of 10-500 μM, achieving a sensitivity of 0.0196 μA/μM, LOD of 5.7 μM and LOQ of 18.8 μM was obtained. Additionally, the cell was tested toward the detection of oxalate within a spiked synthetic urine sample, obtaining recoveries of 104%. This work highlights how, using mixed material composites, excellent electrochemical performance can be obtained at a reduced material cost, while also greatly improving the sustainability of the system.
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Affiliation(s)
- Iana V.
S. Arantes
- Faculty
of Science and Engineering, Manchester Metropolitan
University, Chester Street, Manchester M1 5GD, U.K.
- Departmento
de Química Fundamental, Instituto de Química, Universidade de São Paulo, São Paulo, SP 05508-000, Brazil
| | - Robert D. Crapnell
- Faculty
of Science and Engineering, Manchester Metropolitan
University, Chester Street, Manchester M1 5GD, U.K.
| | - Elena Bernalte
- Faculty
of Science and Engineering, Manchester Metropolitan
University, Chester Street, Manchester M1 5GD, U.K.
| | - Matthew J. Whittingham
- Faculty
of Science and Engineering, Manchester Metropolitan
University, Chester Street, Manchester M1 5GD, U.K.
| | - Thiago R. L. C. Paixão
- Departmento
de Química Fundamental, Instituto de Química, Universidade de São Paulo, São Paulo, SP 05508-000, Brazil
| | - Craig E. Banks
- Faculty
of Science and Engineering, Manchester Metropolitan
University, Chester Street, Manchester M1 5GD, U.K.
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Crapnell RD, Adarakatti PS, Banks CE. Electroanalytical overview: the sensing of carbendazim. ANALYTICAL METHODS : ADVANCING METHODS AND APPLICATIONS 2023; 15:4811-4826. [PMID: 37721714 DOI: 10.1039/d3ay01053h] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/19/2023]
Abstract
Carbendazim is a broad-spectrum systemic fungicide that is used to control various fungal diseases in agriculture, horticulture, and forestry. Carbendazim is also used in post-harvest applications to prevent fungal growth on fruits and vegetables during storage and transportation. Carbendazim is regulated in many countries and banned in others, thus, there is a need for the sensing of carbendazim to ensure that high levels are avoided which can result in potential health risks. One approach is the use of electroanalytical sensors which present a rapid, but highly selective and sensitive output, whilst being economical and providing portable sensing platforms to support on-site analysis. In this minireview, we report on the electroanalytical sensing of carbendazim overviewing recent advances, helping to elucidate the electrochemical mechanism and provide conclusions and future perspectives of this field.
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Affiliation(s)
- Robert D Crapnell
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester M1 5GD, UK.
| | - Prashanth S Adarakatti
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester M1 5GD, UK.
| | - Craig E Banks
- Faculty of Science and Engineering, Manchester Metropolitan University, Chester Street, Manchester M1 5GD, UK.
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