Considerations Using Additive Manufacture of Emulsion Inks to Produce Respiratory Protective Filters Against Viral Respiratory Tract Infections Such as the COVID-19 Virus

Thiol-Acrylate polyHIPEs via Facile Layer-by-Layer Photopolymerization

A highly reactive thiol-ene high internal phase emulsion based on the monomers 1,6-hexanediol diacrylate and tris 2-(3-mercaptopropionyloxy)ethyl isocyanurate was developed for the purpose of light-driven additive manufacturing, resulting in highly porous customizable poly(high internal phase emulsion) materials. The formulation was specifically designed to facilitate short irradiation times and low amounts of photoinitiator. Furthermore, the developed emulsion does not rely on employing harmful solvents to make scale-up and industrial applications feasible. The selected thiol was added to the printing formulation as a chain-transfer agent, decreasing the brittleness of the acrylate-based system and potential of oxygen inhibition. The thickness of the printed layers lay <50 μm, and the average pore size of all samples was <5 μm.

Surfactant-free gelatin-stabilised biodegradable polymerised high internal phase emulsions with macroporous structures

High internal phase emulsion (HIPE) templating is a well-established method for the generation of polymeric materials with high porosity (>74%) and degree of interconnectivity. The porosity and pore size can be altered by adjusting parameters during emulsification, which affects the properties of the resulting porous structure. However, there remain challenges for the fabrication of polyHIPEs, including typically small pore sizes (∼20-50 μm) and the use of surfactants, which can limit their use in biological applications. Here, we present the use of gelatin, a natural polymer, during the formation of polyHIPE structures, through the use of two biodegradable polymers, polycaprolactone-methacrylate (PCL-M) and polyglycerol sebacate-methacrylate (PGS-M). When gelatin is used as the internal phase, it is capable of stabilising emulsions without the need for an additional surfactant. Furthermore, by changing the concentration of gelatin within the internal phase, the pore size of the resulting polyHIPE can be tuned. 5% gelatin solution resulted in the largest mean pore size, increasing from 53 μm to 80 μm and 28 μm to 94 µm for PCL-M and PGS-M respectively. In addition, the inclusion of gelatin further increased the mechanical properties of the polyHIPEs and increased the period an emulsion could be stored before polymerisation. Our results demonstrate the potential to use gelatin for the fabrication of surfactant-free polyHIPEs with macroporous structures, with potential applications in tissue engineering, environmental and agricultural industries.

Synthesis and Applications of Elastomeric Polymerized High Internal Phase Emulsions (PolyHIPEs)

Polymer foams (PFs) are among the most industrially produced polymeric materials, and they are found in applications including aerospace, packaging, textiles, and biomaterials. PFs are predominantly prepared using gas-blowing techniques, but PFs can also be prepared from templating techniques such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPEs have many experimental design variables which control the physical, mechanical, and chemical properties of the resulting PFs. Both rigid and elastic polyHIPEs can be prepared, but while elastomeric polyHIPEs are less commonly reported than hard polyHIPEs, elastomeric polyHIPEs are instrumental in the realization of new materials in applications including flexible separation membranes, energy storage in soft robotics, and 3D-printed soft tissue engineering scaffolds. Furthermore, there are few limitations to the types of polymers and polymerization methods that have been used to prepare elastic polyHIPEs due to the wide range of polymerization conditions that are compatible with the polyHIPE method. In this review, an overview of the chemistry used to prepare elastic polyHIPEs from early reports to modern polymerization methods is provided, focusing on the applications that flexible polyHIPEs are used in. The review consists of four sections organized around polymer classes used in the preparation of polyHIPEs: (meth)acrylics and (meth)acrylamides, silicones, polyesters and polyurethanes, and naturally occurring polymers. Within each section, the common properties, current challenges, and an outlook is suggested on where elastomeric polyHIPEs can be expected to continue to make broad, positive impacts on materials and technology for the future.

Hydro electroactive Cu/Zn coated cotton fiber nonwovens for antibacterial and antiviral applications

In this study, Cu/Zn galvanic electrodes were sputtered on the two surfaces of hydrophilic cotton fiber nonwovens (Cotton) to prepare hydro electroactive Cu/Cotton/Zn composites. When the Cu/Cotton/Zn was used as a functional layer in the face mask, the Cu/Zn galvanic electrodes can be spontaneously activated by water vapor molecules exhaled by the human body and generate galvanic current. Based on this, the hydro electroactive Cu/Cotton/Zn demonstrated excellent antibacterial activity against Escherichia coli and Staphylococcus aureus and could deactivate Enterovirus 71 (EV71) virions transmitted through the respiratory tract by 97.72% after 15 min of contact. Moreover, the Cu/Cotton/Zn did not affect the particle filtration efficiency and breathability of the face mask's polypropylene (PP) melt-blown layer. Furthermore, the cytotoxicity assessment of Cu/Cotton/Zn showed no cytotoxicity, indicating good biological security. Overall, the Cu/Cotton/Zn may provide a new approach to increase the antibacterial and antiviral performance of current personnel protective equipment on the market.

Toward Mass Customization Through Additive Manufacturing: An Automated Design Pipeline for Respiratory Protective Equipment Validated Against 205 Faces

Respiratory protective equipment (RPE) is traditionally designed through anthropometric sizing to enable mass production. However, this can lead to long-standing problems of low-compliance, severe skin trauma, and higher fit test failure rates among certain demographic groups, particularly females and non-white ethnic groups. Additive manufacturing could be a viable solution to produce custom-fitted RPE, but the manual design process is time-consuming, cost-prohibitive and unscalable for mass customization. This paper proposes an automated design pipeline which generates the computer-aided design models of custom-fit RPE from unprocessed three-dimensional (3D) facial scans. The pipeline successfully processed 197 of 205 facial scans with <2 min/scan. The average and maximum geometric error of the mask were 0.62 mm and 2.03 mm, respectively. No statistically significant differences in mask fit were found between male and female, Asian and White, White and Others, Healthy and Overweight, Overweight and Obese, Middle age, and Senior groups.

Applications of additive manufacturing (AM) in sustainable energy generation and battle against COVID-19 pandemic: The knowledge evolution of 3D printing

Sustainable and cleaner manufacturing systems have found broad applications in industrial processes, especially aerospace, automotive and power generation. Conventional manufacturing methods are highly unsustainable regarding carbon emissions, energy consumption, material wastage, costly shipment and complex supply management. Besides, during global COVID-19 pandemic, advanced fabrication and management strategies were extremely required to fulfill the shortfall of basic and medical emergency supplies. Three-dimensional printing (3DP) reduces global energy consumption and CO2 emissions related to industrial manufacturing. Various renewable energy harvesting mechanisms utilizing solar, wind, tidal and human potential have been fabricated through additive manufacturing. 3D printing aided the manufacturing companies in combating the deficiencies of medical healthcare devices for patients and professionals globally. In this regard, 3D printed medical face shields, respiratory masks, personal protective equipment, PLA-based recyclable air filtration masks, additively manufactured ideal tissue models and new information technology (IT) based rapid manufacturing are some significant contributions of 3DP. Furthermore, a bibliometric study of 3D printing research was conducted in CiteSpace. The most influential keywords and latest research frontiers were found and the 3DP knowledge was categorized into 10 diverse research themes. The potential challenges incurred by AM industry during the pandemic were categorized in terms of design, safety, manufacturing, certification and legal issues. Significantly, this study highlights the versatile role of 3DP in battle against COVID-19 pandemic and provides up-to-date research frontiers, leading the readers to focus on the current hurdles encountered by AM industry, henceforth conduct further investigations to enhance 3DP technology.