Design and manufacture of one-size-fits-all healthcare face shields for the NHS during the COVID-19 pandemic.

During the COVID-19 pandemic, there was a shortage of personal protective equipment, PPE, which resulted in non-certified PPE being used by healthcare staffs. These would not provide the appropriate protection against the SARS-CoV-2 virus. Together with the local NHS Trust (University Hospitals of Derby and Burton (UHDB) NHS Foundation Trust) and a local small and medium enterprise (SME), Riverside Medical Packaging Ltd, the University of Derby (UoD) developed test protocols for PPE with a one-size-fits-all concept. Building on best practice in reviewing the literature and current design requirements, key design parameters were identified such as a minimum strap width and comfort level for healthcare related Face Shield. Two strap headbands made from fabric and elastomer with linear stiffness of 44.1 ± 0.3 N/m and 149.1 ± 3.1 N/m respectively were tested with respect to fit and comfort on small and large arc-shaped models. There was an exponential change in pressure from the side to the middle of the strap headbands. The high stiffness of the elastomer in a radial set-up influenced the pressure exerted on a wearer's head when the elastomer strap was used. Meanwhile the coefficient of friction between the fabric strap and arc-shaped model influenced the pressure exerted when a fabric strap was used. The ergonomics of the designed Face Shields supported the one-size-fits-all concept, whereby various gender and head circumferences were considered. The findings in this paper will promote new standards in the design of PPE with a one-size-fits-all target.

Effect of Powder Bed Fusion Laser Sintering on Dimensional Accuracy and Tensile Properties of Reused Polyamide 11.

Polyamide 11 (PA11) is a plant-based nylon made from castor beans. Powder bed fusion laser sintering (PBF-LS) is an additive manufacturing process used for PA11 which allows for the reuse of the unsintered powder. The unsintered powder is mixed with virgin powders at different refresh rates, a process which has been studied extensively for most semi-crystalline polyamides. However, there is lack of information on the effect of using 100% reused PA11 powder and the effect of the number of times it is reused on its own, during powder bed fusion laser sintering. This paper investigates the effect of reusing PA11 powder in PBF-LS and the effect of the number of times it is reused on the dimensional accuracy, density and thermal and tensile properties. From the 100% virgin powder to the third reuse of the powder, there is a decrease in powder wastage, crystallinity and tensile strength. These are associated with the polymerisation and cross-linking process of polymer chains, upon exposure to high temperatures. This results in a higher molecular weight and, hence, a higher density. From the fourth reuse to the tenth reuse, the opposite is observed, which is associated with an increase in high-viscosity unmolten particles, resulting in defects in the PBF-LS parts.

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities.

Products produced by additive manufacturing (AM) seek to exploit net shape manufacturing by eliminating or minimizing post-process stages such as machining. However, many applications which include turbo machinery components with tight dimensional tolerances and a smooth surface finish will require at least a light machine finishing stage. This paper investigates the machinability of the additively fabricated INCONEL718 (IN718) alloy produced by laser melting powder bed fusion (LM-PBF) with different levels of spherical porosity in the microstructure. The literature suggests that the band width for laser energy density, which combines the various scan process parameters to obtain a low spherical type porosity in the LM-PBF IN718 alloy (~1%), has wide breadth. With the increasing laser energy density and above a threshold, there is a rapid increase in the spherical pore size. In this paper, three tube samples each with different levels of spherical porosity were fabricated by varying the laser energy density for LM-PBF of the IN718 alloy within the stable and higher energy density range and the porosity measured. A low laser energy density was avoided due to balling up, which promotes highly irregular lack of fusion defects and poor consolidation within the alloy microstructure. An orthogonal turning test instrumented, with a three-component dynamometer to measure the cutting forces, was performed on AM produced IN718 tube samples under light cut conditions to simulate a finish machining process. The orthogonal turning tests were also performed on a tube sample obtained from the wrought extruded stock. The machining process parameters, which were studied include varying the cutting speed at three levels, at a fixed feed and under dry cut conditions for a short duration to avoid the tool wear. The results obtained were discussed and a notable finding was the higher rate of built-up-edge formation on the tool tip from the AM samples with a higher porosity and especially at a higher cutting speed. The paper also discusses the mechanisms that underpin the findings.

Antibacterial properties of silver nanoparticles grown in situ and anchored to titanium dioxide nanotubes on titanium implant against Staphylococcus aureus.

Medical grade titanium alloy, Ti-6Al-4V, with TiO2 nanotubes (TiO2-NTs) grown on the surface and then decorated with silver nanoparticles (Ag NPs) is proposed to enhance the antimicrobial properties of the bone/dental implants. However, the decoration with Ag NPs is not consistent and there are concerns about the direct contact of Ag NPs with human tissue. The aim of this study was to achieve a more even coverage of Ag NPs on TiO2-NTs and determine their biocidal properties against Staphylococcus aureus, with and without a top coat of nano hydroxyapatite (nHA). The decoration with Ag NPs was optimised by adjusting the incubation time of the TiO2-NTs in a silver ammonia solution, and using biocompatible δ-gluconolactone as a reducing agent. The optimum incubation in silver ammonia was 7 min, and resulted in evenly distributed Ag NPs with an average diameter of 47.5 ± 1.7 nm attached to the surface of the nanotubes. The addition of nHA did not compromise the antimicrobial properties of the materials; high-resolution electron microscopy showed S. aureus did not grow on the composite with nHA and with >80% biocidal activity measured by the LIVE/DEAD assay, also limited lactate production. Dialysis experiment confirmed the stability of the coatings, and showed a slow release of dissolved silver (3.27 ± 0.15 µg/L over 24 h) through the top coat of nHA.

Multilayered composite coatings of titanium dioxide nanotubes decorated with zinc oxide and hydroxyapatite nanoparticles: controlled release of Zn and antimicrobial properties against Staphylococcus aureus.

Purpose: This study aimed to decorate the surface of TiO2 nanotubes (TiO2 NTs) grown on medical grade Ti-6Al-4V alloy with an antimicrobial layer of nano zinc oxide particles (nZnO) and then determine if the antimicrobial properties were maintained with a final layer of nano-hydroxyapatite (HA) on the composite. Methods: The additions of nZnO were attempted at three different annealing temperatures: 350, 450 and 550 °C. Of these temperatures, 350°C provided the most uniform and nanoporous coating and was selected for antimicrobial testing. Results: The LIVE/DEAD assay showed that ZnCl2 and nZnO alone were >90% biocidal to the attached bacteria, and nZnO as a coating on the nanotubes resulted in around 70% biocidal activity. The lactate production assay agreed with the LIVE/DEAD assay. The concentrations of lactate produced by the attached bacteria on the surface of nZnO-coated TiO2 NTs and ZnO/HA-coated TiO2 NTs were 0.13±0.03 mM and 0.37±0.1 mM, respectively, which was significantly lower than that produced by the bacteria on TiO2 NTs alone, 1.09±0.30 mM (Kruskal-Wallis, P<0.05, n=6). These biochemical measurements were correlated with electron micrographs of cell morphology and cell coverage on the coatings. Conclusion: nZnO on TiO2 NTs was a stable and antimicrobial coating, and most of the biocidal properties remained in the presence of nano-HA on the coating.