High-throughput and versatile design for multi-layer coating deposition using lab automation through...

Area of Science:

• Materials Science and Engineering
• Nanotechnology
• Chemical Engineering

Background:

• Laboratory-scale nanomaterial synthesis is prone to human error, impacting reproducibility and consistency.
• Existing commercial automated layer-by-layer (LbL) devices are expensive and lack flexibility, hindering academic research.
• Precise, repetitive tasks in LbL coating are susceptible to fatigue-induced errors and subjectivity.

Purpose of the Study:

• To design and fabricate a novel, inexpensive automated multi-beaker dip coater for LbL processes.
• To enable the synthesis of nano cerium oxide/polymer coatings and nano ceria films with enhanced reproducibility.
• To provide an accessible automation solution for academic institutions and research laboratories.

Main Methods:

• Fabrication of a large-scale (90 cm horizontal axis) automated dip coater using off-the-shelf electronics.
• Integration of open-source software for precise control of sample path and timing (±0.01 mm precision).
• Utilization of 3D-printed components to maximize simultaneous substrate coating and minimize waste.

Main Results:

• Successful demonstration of automated layer-by-layer (LbL) dip coating for nano cerium oxide/polymer coatings.
• Synthesis of nano ceria films achieved via a successive ionic layer adsorption and reaction (SILAR) method.
• The developed instrument significantly improves sample production rate and reduces material waste.

Conclusions:

• The novel automated LbL dip coater offers a cost-effective and flexible solution for nanomaterial synthesis.
• Automation enhances the reproducibility and consistency of nano cerium oxide coatings and films.
• The design facilitates further automation possibilities, including advanced software control and sensor integration.