Project Nexus - a collaboration between Photocentric, Sartorius, Metamorphic, CPI, the University of Sheffield, and Imperial College London, is developing new sustainable materials for application in single-use bioprocessing equipment such as bioreactors.
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The Role of Sustainable Materials in Additive Manufacturing
Jeremy Pullin, Head of AM & Manufacturing Technology of Sartorius said: “The goals at the heart of the Project Nexus go beyond simply enabling us to unlock the applications of today. They also allow us to realise the future obligations of us all, through the development of sustainable material formulations. Sartorius is committed, excited and proud to work alongside an amazing consortium of partners to bring this vision to reality.”
Single-Use Technologies (SUTs) and Their Benefits
Single-Use Technologies (SUTs) offer numerous benefits, including faster setup and flexible process configurations, while contributing to the reduction of resources like water, electricity, and caustic chemical usage. Although their waste contributes only about 0.002% to global plastic waste, this project aims to further enhance the advantages of SUTs by introducing sustainable material formulations for additive manufacturing.
Innovative 3D Printing and Bio-Based Resins
Through £1.9m of funding via the Innovate UK (IUK) - Sustainable Medicines Manufacturing Innovation: Collaborative R&D programme, Project Nexus brings together extensive expertise across advanced manufacturing automation, digital design and optimisation, as well as material innovation and bioprocessing, to pioneer the future of additive manufacturing (AM) of bioreactors at scale.
The project aspires to offer a greener alternative to SU bioreactors with enhanced circularity and end-of-life pathways, all while retaining the flexibility of disposable systems.
Technological Innovation and Collaboration in Biopharma
Paul Holt, founder and managing director of Photocentric said: “Through harnessing the advanced capabilities of our latest 3D Printing innovation, JENI, we’re really excited to be part of this important partnership and the development of a new generation of cost effective, sustainable solutions for biopharma.”
Photocentric’s latest technology innovation, JENI – a fully automated digital mass manufacturing platform, will be utilised, alongside use of newly developed bio-based, eco-friendly materials.
Enhancing Circularity and Sustainability in Bioreactors
By utilising advanced 3D printing technology and newly developed eco-friendly, bio-based resins to produce thermosets that can be autoclaved for reuse, Project Nexus aims to tackle current challenges and enhance sustainability through greater circularity - aligning with government targets for reducing waste and promoting sustainable manufacturing.
Focus on Bio-Based Resins for Biopharmaceutical Manufacturing
Tony Jackson, Director of Formulation at CPI said: "We’re excited to contribute our expertise in material innovation to Project Nexus. By developing a high-performance, bio-based resin tailored for bioreactors, we are enabling a more sustainable future for biopharmaceutical manufacturing. Our focus on circularity and end-of-life solutions ensures that this project not only advances technological capabilities but also drives meaningful progress towards net zero goals. We look forward to collaborating with our partners to redefine the role of additive manufacturing in the sector."
Collaboration Across Academia and Industry for Innovation
Maria Papathanasiou and Cleo Kontoravdi at Imperial College London said: “We are very excited for this opportunity to demonstrate the translational capabilities of digital design space for the advancement of sustainable biopharmaceutical manufacturing by design.”
Testing, Impact Assessment, and Future of Additive Manufacturing
The bioreactors will be tested for pharmaceutical R&D and point-of-care manufacturing, with potential reuse in industrial biotechnology for green chemical production. In addition to this, the technical, economic, and environmental impact will be assessed, highlighting the benefits of AM technology in reducing waste and enhancing efficiency through material circularity and system flexibility.
The Future of Bioprocessing and Resource Efficiency
Manolis Papastavrou, Director at Metamorphic said: “We are excited to be working alongside leading experts from industry and academia to address one of the biggest challenges faced by the bioprocessing industry today. Project Nexus embodies our commitment to innovation; we will be pushing the boundaries of bioreactor performance and resource efficiency by leveraging the design freedom that Additive Manufacturing has to offer.”
Jose Casamayor Alarco, technical fellow at University of Sheffield AMRC said, “We're excited to contribute the AMRC's wealth of experience in sustainable design engineering to Project Nexus. This collaborative initiative will be a significant step in making the biopharmaceutical sector more sustainable, ultimately advancing the UK's net zero ambitions.”
Project Nexus: Progress and Future Updates
Project Nexus is fully established and set to deliver over the next 24 months. Further updates will be uncovered later as this project progresses.
