(422a) Process Automation Development of 3D Printed Micro-Factories

Additive manufacturing techniques have become increasingly widespread, with a range of applications including food industry to rocket engineering. However, these methods seem not to have been adopted in the chemical industry. Main reasons are that printed parts typically need to handle high pressure and temperature, harsh chemical environments, operate robustly for long hours and reused. Tackling these issues, we propose the 3D printing of a PEEK microfactory. Creating and testing in practice a flexible PEEK systemized framework for continuous chemical processing¹. An end-to-end printed configuration converting reagents and/or solvents to formulated products. Capable of continuous flow synthesis with most of the operations, as pressure setting, automated. Compact structures that are versatile to redesign and rearrange to adapt to specific process requirements. This printed configuration is designed to perform multiple unit operations in flow, including reaction, liquid-liquid extraction, and separation. Focus is on achieving end-to-end formulation in a single chip. This reaction platform incorporates custom-designed and methodically calibrated components like an air driven back pressure regulator, inline printed mixing patterns and use of capillary membranes. To demonstrate its commercial potential industrial equipment is integrated. A Bronkhorst pressure controller along with Festo solenoid valves is utilized to manipulate nitrogen from a high-pressure gas cylinder. Temperature and pressure sensors provide constant monitoring of the values among distinct domains. Correlation of process information and chemical analysis data provides valuable and interpretable information to efficiently assess manufacturing system performance. All gathered data is coupled with algorithmic optimization routes. Material selected for the project, PEEK has a superior strength-to-weight ratio, along with excellent chemical resistance and high heat capacity. Furthermore, is a fully recyclable material. These facts render PEEK filament an ideal additive material.

¹ Christopher P.Breen, Anirudh M.K.Nambiar, Timothy F.Jamison, KlavsF.Jensen. Ready, Set, Flow! Automated Continuous Synthesis and Optimization. Volume 3, Issue 5, May 2021.