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Easy-to-perform and cost-effective fabrication of continuous-flow reactors and their application for nanomaterials synthesis

Easy-to-perform and cost-effective fabrication of continuous-flow reactors and their application for nanomaterials synthesis
Easy-to-perform and cost-effective fabrication of continuous-flow reactors and their application for nanomaterials synthesis
The translation of continuous-flow microreactor technology to the industrial environment has been limited by cost and complexity of the fabrication procedures, and the requirement for specialised infrastructure. In the present study, we have developed a significantly cost-effective and easy-to-perform fabrication method for the generation of optically transparent, continuous-flow reactors. The method combines 3D printing of master moulds with sealing of the PDMS channels’ replica using a pressure-sensitive adhesive tape. Morphological characterisation of the 3D printed moulds was performed, and reactors were fabricated with an approximately square-shaped cross-section of 1 mm^2. Notably, they were tested for operation over a wide range of volumetric flow rates, up to 20 ml/min. Moreover, the fabrication time (i.e., from design to the finished product) was <1 day, at an average material cost of ~£5. The flow reactors have been applied to the production of both inorganic nanoparticles (silver nanospheres) and organic vesicular systems (liposomes), and their performance compared with reactors produced using more expensive and laborious fabrication methods. Numerical simulations were performed to characterise the transport of fluids and chemical species within the devices. The developed fabrication method is suitable for scaled-up fabrication of continuous-flow reactors, with potential for application in biotechnology and nanomedicine.
1871-6784
1-7
Cristaldi, Domenico, Andrea
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Yanar, Fatih
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Mosayyebi, Ali
ab9cf6da-58c4-4441-993b-7d03d5d3549a
Garcia Manrique, Pablo
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Stulz, Eugen
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Carugo, Dario
0a4be6cd-e309-4ed8-a620-20256ce01179
Zhang, Xunli
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Cristaldi, Domenico, Andrea
6da2333e-3305-4a8b-996f-e5a844c69cdc
Yanar, Fatih
528029cd-ac53-433f-9908-92a18cae84e5
Mosayyebi, Ali
ab9cf6da-58c4-4441-993b-7d03d5d3549a
Garcia Manrique, Pablo
f42704b0-9c39-4b1b-b31b-eef7a22221b0
Stulz, Eugen
9a6c04cf-32ca-442b-9281-bbf3d23c622d
Carugo, Dario
0a4be6cd-e309-4ed8-a620-20256ce01179
Zhang, Xunli
d7cf1181-3276-4da1-9150-e212b333abb1

Cristaldi, Domenico, Andrea, Yanar, Fatih, Mosayyebi, Ali, Garcia Manrique, Pablo, Stulz, Eugen, Carugo, Dario and Zhang, Xunli (2018) Easy-to-perform and cost-effective fabrication of continuous-flow reactors and their application for nanomaterials synthesis. New Biotechnology, 47, 1-7. (doi:10.1016/j.nbt.2018.02.002).

Record type: Article

Abstract

The translation of continuous-flow microreactor technology to the industrial environment has been limited by cost and complexity of the fabrication procedures, and the requirement for specialised infrastructure. In the present study, we have developed a significantly cost-effective and easy-to-perform fabrication method for the generation of optically transparent, continuous-flow reactors. The method combines 3D printing of master moulds with sealing of the PDMS channels’ replica using a pressure-sensitive adhesive tape. Morphological characterisation of the 3D printed moulds was performed, and reactors were fabricated with an approximately square-shaped cross-section of 1 mm^2. Notably, they were tested for operation over a wide range of volumetric flow rates, up to 20 ml/min. Moreover, the fabrication time (i.e., from design to the finished product) was <1 day, at an average material cost of ~£5. The flow reactors have been applied to the production of both inorganic nanoparticles (silver nanospheres) and organic vesicular systems (liposomes), and their performance compared with reactors produced using more expensive and laborious fabrication methods. Numerical simulations were performed to characterise the transport of fluids and chemical species within the devices. The developed fabrication method is suitable for scaled-up fabrication of continuous-flow reactors, with potential for application in biotechnology and nanomedicine.

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FINAL-Revised_New_Biotech-revised-Jen 2018 - Accepted Manuscript
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More information

Accepted/In Press date: 4 February 2018
e-pub ahead of print date: 6 February 2018
Published date: 2018

Identifiers

Local EPrints ID: 417818
URI: http://eprints.soton.ac.uk/id/eprint/417818
ISSN: 1871-6784
PURE UUID: c4ccb3f3-1296-4a06-a5b3-7336e0c6ab24
ORCID for Eugen Stulz: ORCID iD orcid.org/0000-0002-5302-2276
ORCID for Xunli Zhang: ORCID iD orcid.org/0000-0002-4375-1571

Catalogue record

Date deposited: 14 Feb 2018 17:31
Last modified: 26 Nov 2021 06:26

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Contributors

Author: Fatih Yanar
Author: Ali Mosayyebi
Author: Pablo Garcia Manrique
Author: Eugen Stulz ORCID iD
Author: Dario Carugo
Author: Xunli Zhang ORCID iD

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