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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

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Published on: August 4, 2018

Additive manufacturing of prototype elements with process interfaces for continuously operating manufacturing lines.

Cosima Hirschberg¹, Mikkel Schmidt Larsen¹, Johan Peter Bøtker¹

¹Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2300 Copenhagen, Denmark.

Asian Journal of Pharmaceutical Sciences

|February 28, 2020

Summary

3D printing enables rapid prototyping of continuous mixing equipment and process analytical technology (PAT) interfaces. Dynamic measurement of near-infrared (NIR) spectra from moving powder improves quantitative analysis for blend uniformity.

Keywords:

3D printing Additive manufacturing Continuous mixing Near-infrared spectroscopy

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Area of Science:

Additive Manufacturing
Process Analytical Technology
Spectroscopy

Background:

Rapid prototyping using 3D printing allows for customized complex geometries.
Additive manufacturing is suitable for creating components for continuous production lines and PAT interfaces.

Purpose of the Study:

To demonstrate the use of 3D printing for prototyping continuous mixing equipment and PAT interfaces.
To evaluate dynamic measurement of near-infrared (NIR) spectra for powder mixing analysis.

Main Methods:

Utilized additive manufacturing to prototype continuous mixer elements and PAT interfaces.
Developed a dynamic calibration setup for in-line NIR spectroscopic monitoring of powder flow.
Compared dynamic measurements with static calibration models using Principal Component Analysis (PCA).

Main Results:

3D printed dynamic measurement systems showed greater potential for quantitative analysis compared to static models.
Optimized positioning of PAT interfaces was crucial for assessing blend uniformity.
Longer mixing geometries resulted in improved mixing due to increased residence time and hold-up volume.

Conclusions:

3D printing is a viable method for prototyping integrated continuous mixing and PAT solutions.
Dynamic NIR spectral analysis enhances the quantitative assessment of powder blend uniformity.
Continuous mixer design, including geometry and residence time, significantly impacts mixing efficiency.