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Elbadawi M, Li H, Ghosh P, Alkahtani ME, Lu B, Basit AW, Gaisford S. Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing. ACS SUSTAINABLE CHEMISTRY & ENGINEERING 2024; 12:11155-11166. [PMID: 39091925 PMCID: PMC11289754 DOI: 10.1021/acssuschemeng.4c01439] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/19/2024] [Revised: 06/14/2024] [Accepted: 06/17/2024] [Indexed: 08/04/2024]
Abstract
Selective laser sintering (SLS) is an emerging three-dimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.
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Affiliation(s)
- Moe Elbadawi
- School
of Biological and Behavioural Sciences, Queen Mary University of London, Mile End Road, London E1 4DQ, United
Kingdom
| | - Hanxiang Li
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
| | - Paromita Ghosh
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
| | - Manal E. Alkahtani
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
- Department
of Pharmaceutics, College of Pharmacy, Prince
Sattam bin Abdulaziz University, Alkharj 11942, Saudi Arabia
| | - Bingyuan Lu
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
| | - Abdul W. Basit
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
| | - Simon Gaisford
- UCL
School of Pharmacy, University College London, 29-39 Brunswick Square, London WC1N 1AX, United Kingdom
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Xu F, Gao M, Wang HX, Wu XL, Liu H, Ma C, Yao QT, Zhao HY. Effect of Discharge Voltage on the Microstructure of Graphene/PEKK Composite Samples by Electromagnetic Powder Molding. Polymers (Basel) 2023; 15:3256. [PMID: 37571150 PMCID: PMC10421528 DOI: 10.3390/polym15153256] [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: 07/04/2023] [Revised: 07/24/2023] [Accepted: 07/25/2023] [Indexed: 08/13/2023] Open
Abstract
The light weight, electrical conductivity, environmental friendliness, and high mechanical properties of graphene/PEKK composites make them popular in biomedical, electronic component and aerospace fields. However, the compaction density and carbonization of the specimen influence the microstructure and conductivity of the graphene/PEKK composite prepared by in situ polymerization, so electromagnetic-assisted molding was used to manufacture products to avoid carbonization and enhance the compaction density. The effects of different discharge voltages on the microstructure of the formed graphene/PEKK specimens were compared. Increasing the discharge voltage will lead to a closer distribution of flake graphene in the matrix to improve the compaction density, mechanical performance and conductivity. At the same time, the numerical analysis model was validated by comparison with the compaction density of the experimental results. Based on this research, the stress/strain distribution on the specimen was obtained with increasing discharge voltages.
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Affiliation(s)
- Fan Xu
- School of Mechanical Engineering, Jiangsu University, No. 301 Xuefu Road, Zhenjiang 212013, China; (M.G.); (H.-X.W.); (X.-L.W.); (H.L.)
- School of Mechanical Engineering & Automation, University of Science and Technology Liaoning, No. 189 Qianshan Centre Road, Anshan 114051, China; (C.M.); (Q.-T.Y.)
| | - Ming Gao
- School of Mechanical Engineering, Jiangsu University, No. 301 Xuefu Road, Zhenjiang 212013, China; (M.G.); (H.-X.W.); (X.-L.W.); (H.L.)
| | - Hui-Xiong Wang
- School of Mechanical Engineering, Jiangsu University, No. 301 Xuefu Road, Zhenjiang 212013, China; (M.G.); (H.-X.W.); (X.-L.W.); (H.L.)
| | - Xue-Lian Wu
- School of Mechanical Engineering, Jiangsu University, No. 301 Xuefu Road, Zhenjiang 212013, China; (M.G.); (H.-X.W.); (X.-L.W.); (H.L.)
| | - Hong Liu
- School of Mechanical Engineering, Jiangsu University, No. 301 Xuefu Road, Zhenjiang 212013, China; (M.G.); (H.-X.W.); (X.-L.W.); (H.L.)
| | - Chao Ma
- School of Mechanical Engineering & Automation, University of Science and Technology Liaoning, No. 189 Qianshan Centre Road, Anshan 114051, China; (C.M.); (Q.-T.Y.)
| | - Quan-Tong Yao
- School of Mechanical Engineering & Automation, University of Science and Technology Liaoning, No. 189 Qianshan Centre Road, Anshan 114051, China; (C.M.); (Q.-T.Y.)
| | - Hui-Yan Zhao
- School of Mechanical & Power Engineering, Yingkou Institute of Technology, No. 46 Bowen Road, Yingkou 115014, China;
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Wu C, Xu F, Wang H, Liu H, Yan F, Ma C. Manufacturing Technologies of Polymer Composites-A Review. Polymers (Basel) 2023; 15:polym15030712. [PMID: 36772013 PMCID: PMC9919240 DOI: 10.3390/polym15030712] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2022] [Revised: 01/12/2023] [Accepted: 01/17/2023] [Indexed: 02/04/2023] Open
Abstract
Polymer composites have been widely used in the aviation, aerospace, automotive, military, medical, agricultural and industrial fields due to their excellent mechanical properties, heat resistance, flame retardant, impact resistance and corrosion resistance. In general, their manufacturing process is one of the key factors affecting the life cycle of polymer composites. This article provides an overview of typical manufacturing technologies, including surface coating, additive manufacturing and magnetic pulse powder compaction, which are normally used to reduce the failure behaviour of polymer composites in service so that the quality of composite products can be improved. Advanced polymer composite powder manufacturing processes, the processing mechanism and experimental methods are described, and the influence of different manufacturing processes on the moulding quality is revealed. This investigation can provide suitable methods for the selection of manufacturing technology to improve the quality of polymer composite products.
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Affiliation(s)
- Chenchen Wu
- State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China
- Institutes for Robotics and Intelligent Manufacturing, Chinese Academy of Sciences, Shenyang 110169, China
| | - Fan Xu
- School of Mechanical Engineering and Automation, University of Science and Technology LiaoNing, Anshan 114051, China
- Correspondence: (F.X.); (H.W.)
| | - Huixiong Wang
- Ningbo Sunny Optoelectronic Information Co., Ltd., Yuyao, Ningbo 315400, China
- Correspondence: (F.X.); (H.W.)
| | - Hong Liu
- School of Mechanical and Engineering, Jiangsu University, Zhenjiang 210061, China
| | - Feng Yan
- School of Mechanical Engineering and Automation, University of Science and Technology LiaoNing, Anshan 114051, China
| | - Chao Ma
- School of Mechanical Engineering and Automation, University of Science and Technology LiaoNing, Anshan 114051, China
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Xu F, Gao M, Wang H, Liu H, Yan F, Zhao H, Yao Q. Polymer-based graphene composite molding: a review. RSC Adv 2023; 13:2538-2551. [PMID: 36741177 PMCID: PMC9843696 DOI: 10.1039/d2ra07744b] [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: 12/05/2022] [Accepted: 01/07/2023] [Indexed: 01/18/2023] Open
Abstract
Polymer-based graphene composite products with high mechanical properties, heat resistance, corrosion resistance and electrical conductivity are obtained by different molding technologies. Although these processes conveniently realize the molding of polymer composites, it is often difficult to control the product quality because of the fluctuation of the temperature and pressure threshold. At the same time, a high temperature or external load will carbonize polymer composites or cause excessive porosity to influence the compacted density and electrical conductivity. In this review, additive manufacturing, injection molding, extrusion molding, hot pressing, spark plasma sintering, electromagnetic-assisted molding and other processing methods were introduced. Meanwhile, the powder molding mechanism and material constitutive model were introduced, providing appropriate molding methods and theoretical guidance based on the performance of raw materials and the performance requirements of products.
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Affiliation(s)
- F. Xu
- School of Mechanical Engineering & Automation, University of Science and Technology LiaoNingQianshan Centre Road 189#114051AnshanChina,School of Mechanical Engineering, Jiangsu UniversityXuefu Road 301#Zhenjiang212000China
| | - M. Gao
- School of Mechanical Engineering, Jiangsu UniversityXuefu Road 301#Zhenjiang212000China
| | - H. Wang
- Ningbo Sunny Optoelectronic Information Co., LtdYuyao, 1918#NingboZhejiangChina
| | - H. Liu
- School of Mechanical Engineering, Jiangsu UniversityXuefu Road 301#Zhenjiang212000China
| | - F. Yan
- School of Mechanical Engineering & Automation, University of Science and Technology LiaoNingQianshan Centre Road 189#114051AnshanChina
| | - H. Zhao
- School of Mechanical & Power Engineering, Yingkou Institute of TechnologyBowen Road 46#115014YingkouChina
| | - Q. Yao
- School of Mechanical Engineering & Automation, University of Science and Technology LiaoNingQianshan Centre Road 189#114051AnshanChina
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Mechanical performance of graphene x/poly(ether ketone ketone) composite sheets by hot pressing. Sci Rep 2022; 12:4114. [PMID: 35260773 PMCID: PMC8904769 DOI: 10.1038/s41598-022-08221-0] [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: 11/09/2021] [Accepted: 02/28/2022] [Indexed: 11/25/2022] Open
Abstract
Polymer composites are gradually replacing traditional metal materials in the fields of aviation, aerospace, automotive and medicine due to their corrosion resistance, light weight and high strength. Moulding technology and organization morphology of polymer composite are key elements affecting the quality of products and their application, so a vacuum hot pressing process for graphenex/poly(ether ketone ketone) (PEKK) (x = 0%, 2%, 3%, 4%, 5%, 6%) composite powders is explored with particularly designed moulding parameters to achieve high conductive properties and good mechanical properties in graphene/PEKK composite sheet with thickness of 1.25 mm and diameter of 80 mm. The vacuum environment ensures that the graphene is not oxidized by air during hot pressing molding, which is essential for achieving conductive property in the graphene/PEKK composite; The hot pressing temperature of each graphene/PEKK composite powder is higher than glass transition temperature but lower than melting temperature, which ensures the graphene/PEKK composite powders is fully compacted and then graphene is fully lapped in the composite sheet. In addition, the graphene/PEKK composite sheet shows conductive property when the graphene content increases to 3wt%, and then the conductivity of the composites increases and then decreases with a peak value at 5wt% with increasing graphene content. By comparing the mechanical properties and microstructure morphology of the graphene/PEKK composite sheets, it was obtained that graphene content has an obvious effect on the mechanical properties of the composites, e.g., the mechanical properties will be increased as the graphene content increasing when graphene content is more than 3%. The graphene distribution law of the composite material with different graphene contents is analysed using a scanning electron microscope (SEM).
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