Progressing Flow Chemistry through the Additive Manufacturing of Novel Functionalised Systems

项目背景（识别问题及其重要性和与可持续性的相关性）流动化学已经证明比传统的批式化学系统有改进。改进的质量和热传递使化学产品的生产更加有效和高效，并且通过最大限度地减少操作人员的接触，连续性本质上提高了安全性。流体系统在工业上广泛应用于从石油化工到特种化学品（如纳米颗粒）的批量生产，显示了该技术的多功能性。然而，最初的实验设计和筛选主要是用实验室批处理设备进行的。虽然小型流量系统可用于商业研究，但它们通常使用缺乏灵活性的标准化组件。增材制造（AM）可用于开发更灵活的系统，用于多种化学合成，包括多相催化，光和电化学。增材制造的发展增加了打印部件的设计自由度。新颖的方法克服了诸如结构支撑的要求等限制。聚合物由于其可控制的特性，如形状保真度和适用于不同的3D打印方法，在微流体系统的制造中有着广泛的应用。然而，化学相容性、耐温性、材料浸出性和透气性等方面的限制尚未得到适当的解决。增材制造通过允许在现场生产和试验来解决流动系统的可访问性问题。这使研究人员能够更容易地以一种更可持续的方式试验新的反应，也有可能为欠发达的研究地点提供更复杂的反应堆装置。解决围绕典型增材制造材料的问题，同时利用增材制造的优势是这个项目的重点。由于其化学惰性、高透明度和物理公差，玻璃是增材制造中使用的理想材料。传统的3D打印技术采用一层一层的材料形成，遭受层间变形。更新颖的技术利用体积打印，生产合适质量的玻璃结构，用于管状流道。将开展工作，确定和评估使用增材制造玻璃结构生产流动系统的合适方法。流动系统的进一步发展利用PAT（过程分析技术）和计算机化系统进行机器学习，以实现快速过程优化。增材制造使传感器在制造时集成到组件中，最大限度地减少了生产时间，并实现了新的分析技术。附加功能化可以整合反应性组分，例如用于酶促反应的负载催化剂。利用玻璃和通过增材制造实现功能化的流动系统的开发将扩展流动化学的应用。流动系统固有的可持续性将进一步受益于通过集成组件进行反应监测的便利性，反应功能将为新的合成技术打开大门。相关分析技术将用于评估增材制造玻璃的透明度、纯度和结构强度。开发的系统还将通过反应试验进行评估，以监测所有分析结果的性能，从而进一步开发和优化。

Project background (identification of the problem and its importance and relevance to sustainability) Flow chemistry has demonstrated improvements over traditional batch type chemistry systems. Improved mass and heat transfer allows more effective and efficient production of chemical products, and the continuous nature inherently improves safety by minimising operator exposure. Flow systems are industrially utilised for processes ranging from petrochemicals to bulk manufacture of specialty chemicals such as nanoparticles showing the versatility of the technology. However, initial experimental design and screening is predominantly performed with lab-based batch equipment. While small scale flow systems are available commercially for research, they typically use standardised components that lack flexibility. Additive Manufacturing (AM) can be utilised to develop more flexible systems for a range of chemical synthesis including heterogeneous catalysis, photo and electrochemistry. Developments in AM has enabled increasing design freedom for printed parts. Novel methodologies have overcome restrictions such as the requirement for structural supports. Polymers have extensive use in the fabrication of microfluidic systems due to their controllable properties such as shape fidelity and applicability to different 3D printing methods. However limitations around chemical compatibility, temperature tolerance, material leeching and air-permeability are yet to be suitably addressed. Additive manufacturing addresses the accessibility to flow systems by allowing them to be produced and trialled on site. This enables researchers to more readily trial novel reactions in a more sustainable way and also has the potential to provide access to more complicated reactor setups to less developed research locations. Solving the issue around typical AM materials while also utilising the benefits of AM is the focus of this project. Proposed solution and methodology Glass is a desirable material for use in AM due to its chemical inertness, high transparency and physical tolerances. Conventional 3D printing techniques employ layer by layer formation of materials that suffer inter-layer deformities. More novel techniques utilise volumetric prints, producing glass structures of suitable quality for use as tubular flow paths. Work will be undertaken to identify and assess suitable methodologies for producing flow systems using AM glass structures. Further development of flow systems utilises PAT (process analytical techniques) and computerised systems for machine learning for rapid process optimisation. AM enables the integration of sensors into components as they are fabricated, minimising production time and enabling novel analytical techniques. Additional functionalisation can integrate reactive components such as supported catalysts for uses such as enzymatic reactions. Development of a flow system utilising glass and the functionalisation enabled through AM will expand the applications of flow chemistry. The inherent sustainability of flow systems will further benefit from ease of reaction monitoring through integrated components and reactive functionality will open the door to novel synthesis techniques. Relevant analysis techniques will be used to assess AM glass transparency, purity and structural strength. Developed systems will also be assessed through reaction trials to monitor performance with results from all analysis leading into further development and optimisation.