Progressing Flow Chemistry through the Additive Manufacturing of Novel Functionalised Systems

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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.