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

这个i-Corps项目的更广泛的影响/商业潜力是开发一种自限电喷雾沉积制造技术。从植入物的生物相容剂到航空航天中的防腐应用，材料涂层无处不在。然而，大多数微米和纳米级制造技术在经济上是不可行的。这项拟议的技术旨在处理纳米颗粒和生物材料，并可能在原本昂贵得令人望而却步的设备和结构中实现这些材料。广泛的添加制造(AM)的出现导致了3D打印部件比以往任何时候都更加复杂和可定制。拟议的技术可用于对这些部件进行涂装和升级，并实现高度自动化。此外，人们对仿生材料作为一种新的特殊材料的兴趣也在增长，而拟议的技术代表了一种产生这些结构的低成本方式。此外，建议的技术还可以用于医疗应用，可能会将先进疗法和功能植入物的覆盖范围扩大到更广泛的患者。这个i-Corps项目基于自限电喷雾沉积技术的开发，这是一种利用静电力来制造高度定向的保形涂层的制造技术。这项拟议的技术旨在使用单个固定喷嘴在环境条件下对3D对象进行涂层，并且类似的效果允许在绝缘基板上定向微米级2D导电图案。自限电喷雾沉积技术已经证明与几种工业相关材料的兼容性，包括聚合物、治疗性分子(例如免疫调节剂、DNA疫苗、蛋白质)、纳米颗粒和密封屏障。它还与附加制造(AM)零件和小型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微米和纳米级均匀的真正共形涂层。此外，结果实现了接近100%的效率，允许对昂贵材料的低浪费处理。总而言之，这些能力使提议的技术成为在成本高昂的行业实施高科技解决方案的理想选择。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势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.