Integrating Computational Modeling and Experiments for the Additive Manufacturing of Copper-Based Antibacterial...

Area of Science:

• Materials Science
• Surface Engineering
• Biomaterials

Background:

• Antibacterial coatings are crucial for reducing pathogen transmission on high-touch surfaces.
• Developing effective and durable antibacterial surfaces remains a significant challenge.

Purpose of the Study:

• To create copper-based antibacterial coatings on 304 stainless steel using laser powder bed fusion (L-PBF).
• To analyze the nanoscale melting and coalescence processes using molecular dynamics (MD) simulations.
• To evaluate the antibacterial efficacy of the developed coatings.

Main Methods:

• Laser Powder Bed Fusion (L-PBF) for coating fabrication.
• Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM-EDS) for material analysis.
• Molecular Dynamics (MD) simulations for nanoscale process investigation.
• Antibacterial testing against *Escherichia coli* and *Acinetobacter baumannii*.

Main Results:

• Heterogeneous copper distribution observed, with Cu-rich regions up to 69 at. %.
• Localized phase separation confirmed due to rapid solidification and Marangoni convection.
• MD simulations validated experimental findings of copper surface segregation.
• Complete inactivation of *E. coli* and *A. baumannii* within 1 hour.

Conclusions:

• L-PBF can produce copper-based antibacterial coatings on stainless steel with excellent efficacy.
• Understanding nanoscale phenomena aids in optimizing L-PBF for self-disinfecting surfaces.
• The developed coatings offer a promising solution for reducing microbial contamination on frequently touched surfaces.