What changed?

The Impacts and Benefits

Impacts to the Company

3D printing injection moulding tool with straight and curved microchannels has been demonstrated in Professor Gadegaard’s group at University of Glasgow prior to this project. The key feature strictly required on droplet generation microfluidics is 2 or 4 sharp inside corners of T-junction or cross-junction nozzles. In the first year of the project, Euan, the KTP Associate, established an unique multi-stage printing procedure, and successfully fabricated injection moulding tools using a commercial 3D printers and further moulded droplet generation microfluidic parts in PS and COC. Image 4 shows an assembled droplet generation device, and Image 1 the 4 sharp inside corners of the cross-junction.

The established process is under evaluations, including fabricated various nozzle dimensions, i.e., 40μmx40μm, 60μmx60μm and 80μmx80μm, that demonstrates the potential for quick and cost-effective prototyping microfluidics in thermoplastic materials for Sphere’s microdroplet applications. Euan and Sphere’s microfluidics team are currently improving microchannel sealing and surface modification steps. Next, Euan and the team will explore the full potential and expand the capabilities of the developed approach for design and fabrication of more complex microfluidics, such as droplet sorting devices with embedded electrodes, 3D microfeatures with different heights for different purposes, and integration of multiple functional units, etc.

Impacts to the Academic Team 

Euan has made significant academic and technical advanced during his time on the KTP project. Although my research lab had already proven the principle of using 3D printing to make tools for injection moulding, we had never pushed for their use in technical applications with strict dimensional control. Euan demonstrated that our original method fell short of delivering the quality required, thus embarking on a novel approach of completely changing the print process. Normally parts are printed by sequential layer exposures, but Euan incorporated a staged approached where details of the devices were printed independently. As a result, he has now developed a process which will be used by SphereBio in the future to develop new products.

In parallel Euan has developed strong analytical skills supported by software development to analyse the tooling and provide rigorous metrics for quality control. This is a very important skill in an industrial environment and his processes have a very positive effect on a research environment where such practises are well received.

Finally, Euan has been trained on our injection moulding equipment and has also been attending external training sessions to increase his skills in this area. This means that Euan is now fully autonomous on operating this complicated piece of equipment.

In short, Euan’s approach has impacted on researchers in the lab in terms of analytics, development of standard operating protocols and general project management. Skills that are sometimes a bit further away from an academic environment.

Impacts to the KTP Associate 

The Associate has gained extensive multidisciplinary expertise through this project. Technical skills development includes proficiency in programming (MATLAB and Python), resulting in the creation of an automated metrology data analysis tool that standardises evaluation processes. Gained significant hands-on experience and knowledge with injection moulding techniques for 3D printed tooling, including professional training from Engel (equipment manufacturer), and can now independently operate equipment, perform tool changes, and troubleshoot complex issues.

The project has provided significant experience in precision CAD (SolidWorks & Fusion 360) design specifically for manufacturing injection moulding tooling and optimizing 3D prints. The Associate successfully pushed 3D printing technological boundaries by producing parts with dimensions significantly smaller than previously demonstrated 200μm at the University of Glasgow (down to 40μm). The creation of novel 3D printed liquid connectors has resulted in valuable intellectual property development.

Additionally, the Associate developed expertise in polymer bonding techniques, designing, and building a bespoke thermal diffusion pneumatic press and establishing bonding parameters for multiple thermoplastics.

Beyond technical skills, the Associate has gained experience working at the interface of academic research and commercial application, developing project management capabilities, and improving communication skills across multidisciplinary teams in both university and industry settings.