I-Corps: Surface Modification of Complex Structures by Self-Limiting Electrospray Deposition

这个I-Corps项目更广泛的影响/商业潜力是开发一种自限制电喷雾沉积制造技术。 材料涂层无处不在，从植入物的生物相容剂到航空航天中的防腐蚀应用。然而，大多数用于微米和纳米级制造的技术在经济上是不可行的。 所提出的技术旨在处理纳米颗粒和生物材料，并且可以在设备和结构中实现这些材料，否则它们将非常昂贵。 广泛的增材制造（AM）的出现导致3D打印部件比以往任何时候都更加复杂和可定制。所提出的技术可用于以高自动化水平涂覆和升级这些部件。 此外，人们对仿生材料作为一类新的非凡材料的兴趣正在增长，并且所提出的技术代表了产生这些结构的低成本方法。此外，所提出的技术可用于医疗应用，这可能会扩大先进的治疗和功能性植入物的范围，以更广泛的patients.This I-Corps项目是基于自限制电喷雾沉积技术的发展，这是一种制造技术，使用静电力来执行高度针对性的保形涂层。所提出的技术被设计为使用单个固定喷嘴在环境条件下涂覆3D物体，并且类似的效果允许在绝缘基板上瞄准微米级2D导电图案。自限性电喷雾沉积技术的相容性已经用几种工业相关材料证明，包括聚合物、治疗分子（例如，免疫调节剂、DNA疫苗、蛋白质）、纳米颗粒和密封屏障。它还与增材制造（AM）零件以及小型2D和3D特征高度兼容。虽然标准静电喷涂在汽车和制药制造中无处不在，甚至可以实现非视线涂层，但所提出的技术旨在实现真正的保形涂层，在微米和纳米级上具有均匀性。此外，结果实现了接近100%的效率，允许对昂贵材料进行低浪费处理。总的来说，这些能力使所提出的技术成为跨行业实施高科技解决方案的理想选择，否则它们将成本高昂。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of a self-limiting electrospray deposition manufacturing technology. Material coatings are ubiquitous, from bio-compatibilizers for implants, to anti-corrosion applications in aerospace. However, most techniques for micro and nanoscale manufacturing are not economically feasible. The proposed technology is designed to process nanoparticles and biomaterials and may implement these materials in devices and structures where they would otherwise be prohibitively expensive. The advent of widespread additive manufacturing (AM) has led to 3D printed parts that are more intricate and customizable than ever before. The proposed technology may be used to coat and upgrade these parts with a high level of automation. In addition, interest is growing in biomimetic materials as a new class of extraordinary materials, and the proposed technology represents a low-cost way to generate these structures. Also, the proposed technology may be used in medical applications that may expand the reach of advanced therapeutics and functional implants to a much wider range of patients.This I-Corps project is based on the development of a self-limiting electrospray deposition technology, which is a manufacturing technique that uses electrostatic forces to perform highly targeted conformal coatings. The proposed technology is designed to coat 3D objects in ambient conditions using a single stationary spray nozzle and a similar effect allows for targeting of micron-scale 2D conductive patterns on insulating substrates. The compatibility of the self-limiting electrospray deposition technology has been demonstrated with several industrially relevant materials including polymers, therapeutic molecules (e.g., immunomodulators, DNA vaccines, proteins), nanoparticles, and hermetic barriers. It is also highly compatible with additive manufacturing (AM) parts and small 2D and 3D features. While standard electrostatic sprays are ubiquitous in automotive and pharmaceutical manufacturing and can even achieve non-line-of-sight coatings, the proposed technology is designed to achieve true conformal coatings with uniformity on the micro and nanoscale. In addition, results achieved efficiencies approaching 100%, allowing for low waste processing of expensive materials. Collectively, these capabilities make the proposed technology ideal for implementing high-tech solutions across industries where they would otherwise be cost prohibitive.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.