By Dr. Fiona Mary Antony, Adira Vaidyanathan (KRÜSS GmbH, Germany, kruss-scientific.com)
Coatings play a critical role in a wide range of industries, from automotive and aerospace to medical devices and consumer electronics. They serve as protective barriers against corrosion, wear, and environmental degradation while also enhancing aesthetics and functional properties such as hydrophobicity, conductivity, or anti-fouling behavior. However, the performance of a coating is only as good as its adhesion to the underlying substrate. Poor adhesion can lead to premature failure in the form of peeling, blistering, or delamination, ultimately compromising product reliability and longevity.
Surface analysis: the foundation of effective coating
Surface analysis plays a vital role in ensuring that coatings adhere properly by assessing the substrate’s physical and chemical properties. Traditional adhesion tests, such as ISO/JIS cross-hatch and ASTM tape tests, only evaluate final adhesion strength but fail to explain why adhesion is strong or weak.
To address this, modern surface free energy analysis provides predictive insights into coatability. Tools such as the KRÜSS Drop Shape Analyser measure key parameters like:
Work of adhesion (WA): Determines the energy required to separate a liquid coating from a solid surface. A higher WA indicates stronger adhesion.
Spreading coefficient (S): Predicts whether a liquid coating will spread or bead on a surface. A positive S value ensures good adhesion, while a negative value signals poor wetting.
Interfacial tension (YSL): Represents the energetic barrier between the coating and the substrate. Lower interfacial tension leads to better bonding and adhesion.
Enhancing coating adhesion with surface treatments
Low-energy surfaces, like untreated PP, exhibit poor adhesion due to their hydrophobic nature. To improve coatability, surface treatments such as:
plasma or corona treatment (modifies surface chemistry)
flame treatment (increases surface oxidation)
primer application (enhances bonding sites)
can be applied. Contact angle measurements before and after these treatments confirm increased surface free energy, leading to better adhesion.
The effectiveness of surface treatment in enhancing adhesion was evaluated by applying a water-based, one-component topcoat (1K) to polyamide (PA) substrates. This system is particularly relevant in printing and packaging applications, where polymer films require strong adhesion for high-quality prints, laminates, and coatings. Due to the inherently low surface free energy of polymeric materials, ensuring proper ink and coating adhesion remains a key challenge in these industries. To address this, Openair-Plasma® treatment was employed at varying intensities to modify surface properties and improve wettability.
Surface characterisation and treatment impact
A crucial factor in achieving strong adhesion in printing and packaging films is surface free energy modification, as it directly influences wettability and coating spreadability. The untreated PA substrate exhibited a total surface free energy of 49.2 mN/m, with a low polar fraction (15.2%), making it less receptive to water-based coatings. As plasma intensity increased, the total surface free energy and polarity rose significantly, improving coating compatibility.
In contrast, the water-based 1K topcoat had a surface tension of 25.0 mN/m, primarily dominated by disperse interactions (19.0 mN/m) and a smaller polar contribution (6.0 mN/m). The increased polar fraction of plasma-treated PA substrates resulted in improved adhesion, which is essential in flexographic and digital printing processes where uniform ink spreading is required.
Adhesion performance and coating durability
For packaging films and printed labels, adhesion strength determines resistance to peeling, abrasion, and mechanical stress. To quantify adhesion, work of adhesion (WA), interfacial tension (YSL), and spreading coefficient (S) between the 1K topcoat and the untreated/differently treated substrate were analyzed. Plasma treatment significantly influenced these adhesion parameters, demonstrating its impact on coating performance.
The untreated PA (PA1) showed the lowest work of adhesion (69.7 mN/m) and the highest interfacial tension, leading to weak ink and coating retention. For medium plasma treatment (PA5), adhesion improved, reducing coating detachment in high-speed printing applications. The highest plasma treatment (PA3) exhibited the strongest adhesion (81.0 mN/m), ensuring long-term durability of coatings on flexible packaging films. The results confirm that Openair-Plasma treatment plays a crucial role in enhancing adhesion by modifying the surface chemistry of polyamide substrates.
Additionally, the cross-cut adhesion test (ISO 2409) validated these findings, showing that higher plasma intensity leads to defect-free coatings suitable for demanding industrial applications. The untreated sample (PA1) showed significant delamination, while medium plasma-treated PA5 demonstrated reduced peeling.
Furthermore, we propose surface free energy and adhesion parameter measurements as a complementary method to traditional cross-cut tape tests. By leveraging KRÜSS ADVANCE software and contact angle analysis, these measurements provide a faster, quantitative, and more objective evaluation of substrate/coating adhesion, reducing dependency on time-consuming mechanical tests.
Industrial coatings: applications, types, and key performance parameters
Industry
Common coating types
Key performance parameters
Automotive
Epoxy primers, PU topcoats, electrocoats
* Corrosion resistance : protects metal components from rust and degradation. * Adhesion strength : ensures coatings remain intact * Flexibility : allows coatings to withstand mechanical stress without cracking
Aerospace
High-performance epoxy systems, PU systems
* Thermal stability: maintains integrity under extreme temperature fluctuations * Weight considerations: lightweight coatings are essential to not impede aircraft performance * UV radiation resistance: prevents degradation from prolonged sun exposure
Marine
Anti-fouling, anti-corrosive
* Saltwater resistance: protects against corrosive marine environments * Biofouling resistance: prevents accumulation of marine organisms on surfaces
Oil and gas
Epoxy and PU coatings
* Chemical resistance: withstands exposure to corrosive substances * Abrasion resistance: endures mechanical wear * Temperature resistance: maintains protective qualities under high-temperature conditions
Construction
Protective paints, sealants
* Weather resistance: shields structures from rain, UV rays, and temperature changes * Aesthetic quality: provides desired color and finish while maintaining performance
Modern adhesion analysis, using tools like the KRÜSS DSA series, transforms the way coatings are evaluated. By leveraging parameters like work of adhesion (WA) and spreading coefficient (S), manufacturers can scientifically predict coating performance rather than relying on traditional pass/fail tests. This data-driven approach leads to:
Optimised coating formulations
Reduced material waste
Improved product reliability
Assessing coating stability through adhesion tests, environmental simulations, and chemical resistance evaluations further bolsters the dependability of coatings across various sectors. By integrating predictive adhesion analysis and surface free energy measurement, businesses can attain high-performance, sustainable coatings that endure even the most demanding environments.
Formulate your nanoparticles fast with high precision and easy scale-up. Apply for a free trial of this advanced crossflow mixing technology to accelerate liposome processing and nanoparticle formulation with highly controlled particle size.
If your work requires you to formulate nanoparticles, particularly for drug delivery, you are encouraged to apply for a free trial of a Micropore AXF Pathfinder. You will need to provide a description of your research project including your current methods and formulation objectives. If we assess that the Pathfinder can provide significant advances for your project, then you could receive the following:
* Free use of a Micropore AXF Pathfinder unit
* Free use of supporting nano particle sizing analysers including fluorescence detection
* Training and support to optimise your formulation procedure
The Micropore Pathfinder is a compact Integrated benchtop unit for faster, cheaper, more efficient and scalable production of nanoparticles via advanced cross-flow mixing. Using a 316 stainless-steel precision engineered membrane, Pathfinder reduces the cost and accelerates the development of genomic medicines from lab bench to manufacturing scale. All this from a mixing device small enough to fit in the palm of your hand, easily disassembles, is simple to clean and requires no single-use consumables! This proven technology has multiple applications including pharmaceuticals/ medicines/ veterinary vaccines/ food/ cosmetics and chemicals.
How to apply
This free trial is open to researchers who work in organisations located in Australian or New Zealand. Priority will be given for projects that require scale up for future trial and manufacturing quantities. PhD and Masters students applications must include a letter of recommendation from their supervisor or manager. Please limit your application to 1 A4 page. Applications are now open.
The free trials will be offered for a period of 3 months starting from June 2025 until end of August 2025.
Exosomes are a type of extracellular vesicle (EV) typically 30-150nm in diameter secreted by most human cells and enable cell-to-cell communication. Exosomes are found in abundance in body fluids including blood, urine, saliva, milk, semen, bile juice, ascites, cystic, bronchoalveolar and gastrointestinal lavage fluid and play a significant role in the transfer of biomolecules like proteins, lipids, RNA, DNA.
Exosomes have been found to be involved in multiple biological roles including immune responses, pregnancy, cardiovascular diseases, central nervous system-related diseases, and cancer progression. The molecular cargo they carry can reflect their cell origin so they are considered to be promising biomarkers for the diagnosis of cancer and other various diseases.
WHY ARE EXOSOMES IMPORTANT?
The study of exosomes is an active area of research which are being explored as a tool for disease diagnosis and treatment. Exosomes can be engineered to deliver diverse therapeutic payloads, including short interfering RNAs, antisense oligonucleotides, chemotherapeutic agents, and immune modulators, with the ability to direct their delivery to a desired target. Research into the characterisation of lipid nanoparticles highlights the importance of understanding and refining these delivery mechanisms for therapeutic applications. Ongoing research is enhancing our ability to harness their therapeutic and diagnostic potential. The need for more standardised purification and analytical procedures to study exosomes will likely reveal their functional heterogeneity.
Exosomes are being explored for their potential use as drug delivery vehicles of therapeutic RNA into specific parts of the body such as the brain in the treatment of neurological disorders including Alzheimer’s disease, Parkinson’s disease, and Huntington’s disease. Research into the role of exosomes in therapeutic applications has highlighted their potential for safe and efficient delivery systems. While there are many benefits in exploring the use of exosomes for the safe and efficient delivery of their cargo, major challenges related to their isolation are highlighting development opportunities.
Therapeutic Applications of Exosomes and Associated Challenges
WHAT ARE THE CHALLENGES IN ISOLATION AND CHARACTERISATION?
Reliable isolation and characterisation of extracellular vesicles (EVs) are critical for advancing drug discovery and play a key role in disease detection and treatment. The ability to quickly identify elevated exosome concentrations, as detailed in the comparative analysis of exosome isolation methods, can signal the onset or progression of disease, offering valuable diagnostic insights. Additionally, leveraging the unique properties of EVs as drug-delivery vehicles presents an exciting and innovative approach to combating various diseases.
However, EVs extracted from bodily fluids in response to specific conditions are highly heterogeneous, varying in size, composition, and function. This complexity makes the characterisation of these vesicles an especially challenging yet essential task for researchers.
The need for precise and accurate characterisation of exosomes will continue to grow as our knowledge of the heterogeneity of EVs, their cargo, and their functions evolves. Exosome identification and isolation have the potential to substantially improve our understanding of the basic biology of exosomes and their use in applied science and technology. Such knowledge will inform the therapeutic potential of exosomes for various diseases, including cancer and neurodegenerative diseases.
With increasing potential for their clinical utilisation, it has become imperative to optimise exosome isolation methods for maximum yield, purity and assay reproducibility. Besides the traditional ultracentrifugation method, there are currently several commercial exosome isolation kits developed based on different principles such as charge neutralisation-based precipitation, gel-filtration, affinity purification using magnetic beads, etc. However, these methods can generate significant challenges in exosome isolation, particularly with yield, purity and quality.
Challenges of Current Exosome Isolation Methods:
Different exosome isolation methods can yield different amounts of exosomes
The size distribution of exosomes can significantly vary among preparations from different isolation methods.
Exosomes isolated from different isolation methods can show differences in their zeta potential
The quality of exosomes can differ from different isolation methods affecting functional applications
High cost of disposable modules/consumables, high shear stress involved and inflexible sample volumes
There is therefore a need for a new technology to improve exosome purification in terms of efficiency, purity, yield, speed and robustness. A standardised approach to exosome isolation and characterisation will enable research dependability and translational success. For more information, read this comprehensive analysis of exosome isolation methods.
Clog-Free Ultra Fast Exosome Purification With Exodus
Traditional methods for isolating exosomes, while effective for size-based separation, often suffer from clogged membrane pores, which disrupt continuous processing. These limitations are addressed in recent advances in exosome isolation technologies. To solve this issue, the EXODUS system uses a unique design that combines advanced oscillation technology with a dual-membrane filter.
Comparison of Traditional Exosome Isolation Methods vs. EXODUS System
Feature
Traditional Methods
EXODUS System
Purity
Moderate; impurities often remain
High; impurities effectively filtered
Yield
Variable and inconsistent
High and reproducible
Processing Speed
Time-consuming (hours to days)
Ultra-fast (minutes to hours)
Risk of Clogging
High due to membrane pore blockages
Low; clog-free design
Scalability
Limited to small volumes
Scalable for high-throughput workflows
Cost of Operation
High; frequent consumable replacements
Cost-efficient; durable components
Ease of Use
Manual steps prone to errors
Automated and user-friendly
Compatibility
Limited sample types
Broad compatibility across samples
HERE’S HOW IT WORKS
Smart Filtration: The system uses periodic negative and air pressure switching to create oscillations on a nanoporous membrane. This allows small impurities, like proteins and nucleic acids, to pass through, while exosomes are retained in a central chamber.
Anti-Clogging Technology: Double harmonic oscillators generate waves and fluid movement that keep particles suspended in liquid. This prevents clogging and particle aggregation, ensuring smooth and efficient operation.
The result is a fast, reliable, and clog-free way to purify exosomes, ideal for research and clinical applications. Recent advancements in automatic, label-free exosome isolation have demonstrated significant improvements in efficiency and yield, offering a breakthrough for researchers.
The EXODUS Exosome Isolation System is an automated platform designed to streamline the purification and enrichment of exosomes. This system leverages advanced nanofiltration and oscillation technologies to provide a fast, efficient, and highly reliable solution for exosome research.
Key Features of the Exodus System:
High Purity and Yield:
Ensures consistent recovery of high-quality exosomes suitable for downstream applications, such as biomarker discovery, therapeutic development, and basic research.
Dual-Membrane Nanofiltration:
Incorporates a nanoporous membrane for precise, label-free separation.
Effectively captures exosomes while filtering out impurities like free nucleic acids and proteins.
Clog-Free Operation:
Designed to overcome common issues with membrane blockages found in traditional methods.
Supports continuous and ultra-fast isolation, ideal for high-throughput workflows.
Automated and User-Friendly:
Intuitive interfaces and automated protocols make it accessible for researchers at any level of expertise.
WHY CHOOSE THE EXODUS SYSTEM?
The EXODUS system addresses key challenges in exosome isolation by providing a reliable, scalable, and reproducible solution. It is ideal for a wide range of applications, including disease biomarker identification, Therapeutic exosome production and Fundamental studies on exosome biology.
With its advanced, compact design, the EXODUS system empowers researchers to focus on advancing their exosome studies, reducing manual intervention, and improving data consistency.
Once exosomes have been isolated and purified, they need to be characterised.
Exosome Characterisation Techniques
WHAT IS NTA?
Nanoparticle Tracking Analysis (NTA) is the method of choice and a standard tool that has assisted exosome researchers for over a decade, providing detailed insights into NTA for exosome characterisation. NTA visualises and measures the light scattering from individual EVs moving under Brownian motion offering high-resolution size and concentration characterisation of EVs in their natural environment.
How is NTA Useful?
Understand the role exosomes play in disease, and how they can be utilised in diagnostic or therapeutic applications, with size and concentration data.
Optimise isolation and purification methods with detailed insight into exosome heterogeneity. Changes in size distribution can often indicate disease stage, which is important in diagnosis.
Easily assess batches to confirm production and sample consistency of EV samples
Detect subpopulations of intact vesicles, common and specific biomarkers, and cargo using fluorescence capabilities.
The newest instrument, NanoSight Pro has evolved to include intelligent NS XPLORER software and enhanced sensitivity. Powered by machine learning, the NanoSight Pro provides guided workflows, automated processing, and automated particle identification to provide easy, quick, and accurate analysis. High sensitivity detection enables very detailed information about samples in both the light scatter and fluorescence modes. For further details, explore the benefits of using nanoparticle tracking analysis, a key tool for exosome characterisation. This allows NanoSight Pro to detect exosomes as small as 30nm in just minutes. Furthermore, samples can be recovered in their native form after the measurement. NTA can detect the presence of antigens on EVs by applying fluorescently labelled antibodies. By enabling specific detection of these biomarkers and cargo, users can better understand the behaviour of extracellular vesicles and decode their messages.
WHAT IS DLS?
Dynamic Light Scattering (DLS), also known as Photon correlation spectroscopy, is a non-invasive, well-established technique for measuring the size and size distribution of molecules and particles typically in the submicron region, and with the latest Malvern Panalytical Zetasizer technology, lower than 1nm. DLS is a complementary technique to NTA and can be used for measuring the size of exosomes. The method employs a monochromatic laser that passes through a liquid suspension of particles. Time-dependent fluctuations in the intensity of scattered light caused by Brownian motion of particles are observed and their velocity or translational diffusion coefficient is measured which can be converted into a hydrodynamic diameter.
While both DLS and NTA follow the Brownian motion of dispersed light from the target particles, they operate in different ways. NTA measures individual particle diffusion. DLS measures changes in the intensity of scattered light on a bulk sample. Both methods offer several different benefits and therefore by combining the two techniques users can take advantage of the complementary information they provide.
NTA can often provide higher resolution size measurements, but DLS can offer a faster assessment of the mean size and polydispersity. For perfectly monodisperse samples both DLS and NTA should give the same result.
DLS is most suitable for particle sizes larger than ~1 micron, for quality control of nanoparticle production and for early detection of aggregates.
NTA is most suited for polydisperse distributions where users require a higher resolution of peaks and want to measure the concentration of nanoparticles.
For NTA, users can selectively look at only a fluorescently tagged part of the distribution, while in DLS fluorescence can affect the measurements and require a filter (e.g. quantum dots).
NTA can detect samples 10-1000 times more dilute than DLS.
DLS can handle a wider concentration range without dilution.
The Zetasizer Advance range of instruments are the most widely used dynamic light scattering (DLS) instruments measuring particle and molecular size, particle charge and particle concentration from less than a nanometer to several microns. Combining novel measurement capabilities together with an artificial intelligence (AI) led approach to data quality assessment, the new Zetasizer systems help gain more insight and further confidence to reliably characterise the size and surface charge of colloids, biomolecular nanoparticles; screen protein formulations for colloidal stability and the presence of aggregates; and, assess the shelf-life and stability of complex formulations.
Building on the legacy of the industry-leading Zetasizer Nano series, the three core models, Zetasizer Lab, Zetasizer Pro and Zetasizer Ultra, can be tailored and quickly upgraded to suit specific application needs.
Each benefit from the latest advances includes:
Adaptive Correlation, a statistically driven approach to produce the best correlation data, without the need for sample filtering to deliver reliable, faster size measurements and added confidence in results.
Multi-Angle Dynamic Light Scattering (MADLS) for calibration-free measurement of particle concentration.
Novel constant current zeta mode – allows for high ionic strength measurements previously not achievable. Improved zeta sensitivity requires much lower sample concentrations for a zeta measurement, saving precious material.
Size Quality Guidance – AI-guided data quality advice allows even a novice without any prior light-scattering knowledge to make sense of sizing data.
The fluorescence filter wheel allows for extended applications with fluorescent samples, like quantum dots. Polarisation filters, both vertical and horizontal polarisation components can be detected, potentially gaining insights into particle rotational diffusion.
Works with OmniTrust: Malvern Panalytical’s compliance solution for the regulated environment
In addition to the above, more than 100k publications are using the Zetasizer.
Would you like to learn more about Exosome isolation characterisation tools? Contact our team for expert consultation.
Contact us for a personal demonstration within your lab using the Malvern Zetasizer Ultra, Malvern NanoSight and EXODUS auto exosome isolation system today! Contact us.
Tissue engineering is an innovative and rapidly evolving field in medical science focused on creating biological substitutes to repair, replace, or enhance the function of damaged tissues and organs. It encompasses regenerative medicine, stem cell therapies, decellularised or engineered organs, and electrospun scaffolds. Applications of tissue engineering include treating burn injuries, diabetic wounds, and diseases that compromise tissue functionality.
The ultimate goal is to develop functional tissues that can mimic or even improve the normal operation of the damaged area. For example, stem cells extracted from a patient’s bone marrow can be grown and differentiated into cartilage cells (chondrocytes). These are then seeded onto an optimised scaffold matrix, designed to mimic the original tissue, and transplanted into the patient.
To achieve success, scientists must understand the tissue’s structure and properties, including its interaction with cellular adhesion, porosity, and biocompatibility.
By analysing scaffold structures with tools like the Phenom SEM, scientists are advancing the possibilities for tissue regeneration in humans. Detailed imaging helps refine scaffold designs and monitor cellular interactions, paving the way for more effective regenerative therapies.
This understanding ensures that engineered tissues can withstand normal functionality while promoting cellular interactions essential for repair and regeneration.
HOW CAN TISSUE ENGINEERING ASSIST WITH WOUND HEALING?
Wound healing is the process of replacement of destroyed or damaged tissue. While closing a wound might seem like the primary goal, it’s equally important to focus on the repair process occurring underneath.
There are different types of wound healing. Wound regeneration is the process of healing tissue fully restoring its normal function. Wound repair is the process of healing tissue without restoring it to its normal function, such as a scar where hair no longer grows.
Within wound healing, there are three different stages including;
Inflammation: Prepares the wound for healing.
Proliferation: Generates new tissue.
Remodelling: Strengthens the new tissue.
Delays in any stage can lead to infections, which tissue-engineered scaffolds can prevent. These scaffolds promote regenerative healing by enhancing wound closure, providing nutrients, and creating an optimal environment for cellular interactions.
Optimising a tissue engineering scaffold is crucial for promoting cellular adhesion, growth, and regeneration. Phenom SEM’s advanced imaging capabilities provide detailed insights into scaffold porosity, fiber thickness, and structural integrity, ensuring these synthetic matrices mimic natural extracellular environments effectively.
Properties like porosity, thickness, and mechanical strength significantly influence the success of wound healing.
HOW ARE TISSUES EXAMINED DURING WOUND HEALING?
Microscopy is an essential tool in wound healing research. Techniques like light, fluorescent, and confocal microscopy allow scientists to examine tissue samples, often stained with hematoxylin and eosin (H&E), to assess the cellular structure and observe changes in the skin’s layers.
Comparison of Microscopy Techniques in Wound Healing
Microscopy Technique
Resolution
Sample Preparation
Applications in Wound Healing
Key Advantages
Light Microscopy
Micrometer scale
Simple staining (e.g., H&E)
Examines overall tissue structure and cellular arrangement
Cost-effective and easy to use
Fluorescent Microscopy
Sub-micrometer
Fluorescent dyes or markers
Highlights specific cell types or proteins in tissue samples
High specificity and contrast
Confocal Microscopy
Nanometer scale
Laser scanning with dyes
Provides 3D imaging and layer-by-layer analysis of wound tissues
High resolution and depth information
Evaluating the Applications of Light, Fluorescent, and Confocal Microscopy
WHY USE SEM IMAGING FOR TISSUE ENGINEERING?
Scanning Electron Microscopy (SEM) provides high-resolution imaging at the nanometer scale, making it invaluable for studying tissue structures and morphologies, as discussed in biomedical research applications. Compared to optical microscopy, SEM offers finer details, a greater depth of field, and elemental analysis capabilities using an Energy Dispersive Spectroscopy (EDS) detector.
The Phenom desktop SEM series is particularly advantageous for tissue engineering offering high-resolution imaging of the tissues or synthetic tissue structures, the ability to observe the presence of cells and to analyse the surface topography.
3D bioprinting combined with SEM imaging enables tissue engineers to examine microstructures and ensure that bioprinted tissues meet necessary specifications for cellular proliferation and mechanical strength.
From the entry-level SEM to a system with access to a larger sample compartment or field emission (FEG) source for ultra-high resolution, low kV imaging with STEM detector, all Phenom SEMs offer high speed, and ease of use with a small footprint. They all come standard with x y stage movements, a digital optical microscope that stays with you throughout the entire time of imaging to help find different locations on your sample, a charge reduction mode that allows users to image samples without having to coat them with a gold or platinum layer, and as well as the ability to add on Python scripting. Different software options provide the ability to measure different parameters that can help promote wound healing, such as porosity measurements, fiber diameter measurements, and tensile strength measurements.
APPLICATIONS OF PHENOM SEM IN TISSUE ENGINEERING
1. Skin Grafts or Bioengineered Skin Substitutes
Skin grafts or bioengineered skin substitutes are the standard of care for treating third-degree burns, where skin damage extends to the hypodermis and nerve endings are destroyed. Skin grafts can help prevent infections and can be autologous – where is skin taken from the same person and then transplanted to that damaged area, or allogeneic, when grafts from another person and transplanted to another patient. Before transplantation, tissues go through decellularisation – a method that removes the cells – to prevent patients from having an immune response that can lead to rejection of the tissue. Decellularisation usually leads to an extensive amount of tissue damage which compromises the success of a skin graft.
The Phenom SEM can evaluate the success of decellularisation processes by assessing tissue porosity and cellular removal. Phenom’s integrated PoroMetric software calculates pore characteristics to analyse tissue damage caused by different decellularisation treatments. Research by Dr. Dominic Dominguez, Application Scientist Nanoscience Instruments, found normal skin had an average porosity of 43.41% compared to skin after Tonicity treatment having an average porosity of 46.2% and Triton X-100 having an average porosity of 62.88%. The results demonstrated that Tonicity treatment had similar per cent porosity compared to the original skin samples and thus preserved tissue structure better than Triton X-100.
Porometric software also indicated that Tonicity treatment removed cells from the tissue, whereas Triton X-100 did not completely remove all the cells and caused more destruction to the tissue compared to using Tonicity. Overall, the Phenom SEM was able to help determine that the Triton X-100 treatment was not successful at removing cells and it actually caused more destruction to the tissue structure compared to the Tonicity treatment.
2. Electrospun Fibers Used as Synthetic Tissue Scaffolds
Electrospun fibers are used as synthetic tissues to mimic the extracellular matrix for cellular migration and proliferation. The needle-based technique applies a voltage to a polymer solution in a syringe which creates fibers that are spun onto a collector to create a scaffold with a specific structure, porosity, and thickness. Changing the reagents helps determine different biomimetic cues in the body. The presence of growth factors can be altered to increase the proliferation of cells, induce cellular migration, or even enhance wound healing.
Phenom SEM imaging can be used to observe the process of electrospinning. Researchers studying lipid-infused electrospun scaffolds used the Phenom to confirm biocompatibility and measure fiber diameters. The Phenom FiberMetric software enabled automatic fiber diameter measurements, revealing that increased lipid concentration decreased fiber size without hindering cellular growth. The control had an average fiber size of 1.5 microns compared to the 10% treatment having an average fiber size of 0.93 microns. The FiberMetrics software can capture multiple measurements within seconds and provides reporting measurements to understand the mechanical properties of the tissue or the tissue’s replacement.
3. Tensile Strength Testing
During the scar formation after a wound is healed, did you know that only 70% of the normal tensile strength is recovered compared to the original skin? Being able to mimic or improve the original tissue’s mechanics is the goal of wound healing. Using an electrospun scaffold can aid with strengthening the mechanical properties, and there are various tools used to measure the mechanical properties as well, such as a mechanical tester or a rheometer.
The Phenom XL with the tensile stage allows users to measure the tensile or compressive strength of a material, to view it live under SEM imaging and to record the force and distance in order to calculate the stress and strain of a material. Another useful feature in the Phenom XL is users can navigate to find the same area of interest previously visited so comparisons can easily be made quickly and easily and it’s not like finding a needle in a haystack.
Impact of Lipid Concentration on Fiber Thickness
WHY CHOOSE PHENOM SEM FOR TISSUE ENGINEERING?
Key features include:
Charge reduction mode for imaging nonconductive samples without coating.
Software tools like PoroMetric and FiberMetric for detailed pore and fiber analyses.
A tensile stage for live mechanical testing.
Versatile detector modes (BSD and SED) for capturing elemental and topographical details.
Phenom SEM combines high resolution at high magnification imaging with an intuitive, easy-to-use interface that allows even novices to quickly obtain their first high-quality results. It offers multiple detector modes including Backscatter detector (BSD) and Secondary Electron Detector (SED) modes as well as elemental identification using the integrated Energy Dispersive Spectrometer (EDS or X-ray) detector. Images can be captured with either the BSD, SED or have both detectors on simultaneously. This percentage can be adjusted to capture the elemental contrast from the backscatter detector and topography from the secondary electron detector.
Phenom’s charge reduction mode and the ability for low kV imaging accommodates insulating and beam-sensitive samples with a resolution of 2.0 nm that reveals the finest details. When imaging non-conductive samples, many users will experience charging on samples, making it difficult to collect an image. One way to fix this problem is by coating samples with gold or platinum. The Phenom charge reduction sample holder and software also can adjust the vacuum settings (high to low) to capture images of nonconductive samples without coating and still run elemental analysis using the EDS detector.
The integrated PoroMetric software allows the user to gather data on the distribution of pores and pore parameters like pore size and aspect ratio. Similarly, Phenom FiberMetric Software enables measurement of micro- and nanofibers. Tensile Sample Holder for Phenom XL allows for tensile testing. By measuring the force required to elongate a specimen to the breaking point, material properties can be determined which will allow designers and quality managers to predict how materials and products will behave in their intended applications.
With the Phenom SEM, tissue engineers can analyse scaffold structures, optimise designs, and ensure successful tissue regeneration, paving the way for new advances in wound healing and tissue engineering.
Would you like to learn more about our Advancing Tissue Engineering analysis and solutions? Contact our team for expert consultation.
To learn more about these innovations and discover even more features of the Phenom SEM or Morphologi 4ID and Mastersizer 3000+, Contact us.
Introducing the new Micromeritics AccuPore Capillary Flow Porometer (CFP) – a fast, and reliable method to determine the size distribution (13nm to 500µm) of through-pores, i.e pores that span from one side of a surface of a material to the other. CFP is a non-destructive technique and an important measurement in the development or production of the sheet-goods used for membranes, separators, filtration media, technical fabrics and more.
Unlike traditional CFP systems, the AccuPore uses a compressor for low-pressure operations (bubble point measurement and large pores) and switches to high-pressure bottled gas for analysis of small pores, reducing the need for expensive high-pressure gas.
The flexible design of the AccuPore CFP makes it simple to move between a variety of sample diameters all within the same sample chamber. A selection of sample supports provide reliable measurements to the highest pressures, even for thin or weak membranes while also reducing gas consumption by up to 95%.
Gas-liquid CFP is a direct complement to mercury intrusion porosimetry (MIP), providing a rich description of pore architecture. The AccuPore is particularly valuable for users requiring high precision in characterising filtration efficiency or material permeability especially for optimising the design and performance of battery separators and fuel cell membranes.
The UNSW RNA Institute is a major part of Australia’s RNA ecosystem, uniting researchers from biology, chemistry, medicine and connecting them with the facilities they need to translate their research into RNA treatments, from cancer therapies to personalised medicines and vaccines. For all the tantalising potential of RNA science, the progress has been stymied by a roadblock of scale – but not anymore!
The Pathfinder PRO 250 from Micropore Technologies meets the need for a faster and cheaper high-throughput manufacturing method. Pathfinder offers a GMP compliant approach from the earliest possible stage through to manufacturing, that is also tuneable in size to access various tissues or specific drug targets.
With the addition of their new Micropore Pathfinder PRO 250 the UNSW RNA Institute can create formulations for the entire spectrum of mRNA–LNP production, ranging from initial discovery volumes to GMP-production scale. The UNSW RNA Institute is looking forward to advancing critical research and contributing to the development of new RNA based therapies.
CONTACT US FOR A DEMO TODAY!
More publications/citations:
Muattaz Hussain, Burcu Binici, Liam O’Connor, Yvonne Perrie, Production of mRNA lipid nanoparticles using advanced crossflow micromixing, Journal of Pharmacy and Pharmacology, Volume 76, Issue 12, December 2024, Pages 1572–1583, https://doi.org/10.1093/jpp/rgae122
Additive manufacturing (AM), or 3D printing, is rapidly transforming industries in Australia, from aerospace and biomedical engineering to automotive and defence. By building up materials layer by layer, AM offers remarkable flexibility and efficiency in creating complex structures. Timely and accurate quality control, however, is a prerequisite for modern additive manufacturing, as excessive or unknown variation in the metal feed powder can lead to non-uniform layering, increased defects, poor surface finish, and even catastrophic failures.
Successful additive manufacturing, particularly with metal powders, relies on quality powder characterisation. The properties of the powders used—especially particle size, shape, packing density, and composition—directly impact the quality, strength, and performance of the final product. In this article, we explore the current landscape of additive manufacturing in Australia and discuss why detailed powder characterisation is essential and the best tools needed for achieving optimal results in AM.
Additive Manufacturing in Australia: Growing Applications and Opportunities
In Australia, AM is expanding, supported by government initiatives and industry interest. This growth is being driven by several leading research centres, which are pushing the boundaries of additive manufacturing across a variety of applications. These institutions contribute to advancements in areas such as aerospace, defence, biomedical engineering, and sustainable materials.
Key Additive Manufacturing Research Centres in Australia
Advanced manufacturing, Industry 4.0, defence, aerospace
Several prominent research centres are driving innovation in additive manufacturing across various industries, including institutions like:
The Australian National Fabrication Facility (ANFF)
The Australian National Fabrication Facility (ANFF) is a network of eight university-based nodes providing AM facilities and expertise for both research and industry. ANFF supports sectors from biotechnology to microelectronics, offering access to cutting-edge fabrication tools and materials.
RMIT University’s Centre for Additive Manufacturing (RCAM)
RMIT University’s Centre for Additive Manufacturing (RCAM) enjoys a reputation as one of the leading innovators for AM in Australia for both aerospace and biomedical applications. The centre specialises in laser-based AM, materials development, and sustainable manufacturing practices.
CSIRO’s Lab22
CSIRO’s Lab22 in Melbourne is a leading AM research hub known for advancing powder bed fusion, direct metal deposition, and cold spray technologies. Lab22 supports projects in the aerospace, defence, and medical sectors.
University of Sydney’s Australian Centre for Additive Biomanufacturing
University of Sydney’s Australian Centre for Additive Biomanufacturing focuses on bioprinting and biofabrication technologies, aimed at producing customised implants and tissues. Collaborating with leading medical institutions, it emphasises innovations in health and regenerative medicine.
Queensland University of Technology (QUT) Advanced Manufacturing Centre
Queensland University of Technology (QUT) Advanced Manufacturing Centre in Brisbane focuses on digital manufacturing, robotics, and additive manufacturing, particularly for medical and industrial applications. Its research supports both metal and polymer AM processes, pushing boundaries in materials science and sustainability.
Swinburne University of Technology’s Factory of the Future
Swinburne University of Technology’s Factory of the Future provides a collaborative environment for developing advanced manufacturing, including AM and Industry 4.0 technologies. With strong industry partnerships, it explores applications in defence, aerospace, and automotive manufacturing.
These and many other AM research facilities in Australia are helping to build sovereign capabilities in industries increasingly adopting AM processes for high-precision applications like aerospace, medical implants, and customised tooling. Given the precision required for these applications, the quality of the raw materials—particularly metal powders—must be tightly controlled. This is where powder characterisation becomes critical.
The Importance of Particle Size in Powder Characterisation
Particle size is a fundamental parameter in powder characterisation that affects how particles flow, pack, and ultimately fuse in the printing process. In metal powder AM, particle size can influence:
Flowability
Small particles often experience issues with flow, clumping together due to electrostatic forces. This can lead to inconsistent layer deposition and defects in the printed part. Ideally, a particle size distribution that supports smooth flow is critical for high-quality printing.
Surface Finish
The particle size determines the minimum layer thickness that can be achieved, impacting the surface finish and resolution of the printed object. Smaller particles can yield finer details but may require more sophisticated handling to avoid clogging or agglomeration.
Sintering and Melting Efficiency
Consistent particle size is essential for uniform melting or sintering, especially in powder bed fusion methods. Particles that are too large or too small can lead to uneven heating and fusion, causing porosity or weak spots in the material.
Particle Shape and Its Influence on Powder Behaviour
Beyond size, particle shape plays a significant role in the behaviour of metal powders.
Common Particle Shapes and Their Effects:
Spherical Particles: Offer better flowability and packing density, ideal for even layering and consistent melting.
Irregular Particles: Challenging to handle due to poor flowability but may provide mechanical interlocking benefits.
Aspect Ratio and Morphology: Influence how particles stack and bond, affecting packing density and mechanical properties.
Particles can range from spherical to irregular or even angular, and each shape presents unique advantages and challenges:
Spherical Particles
Powders with spherical particles typically have better flowability and packing density, making them preferable for many AM processes. This uniform shape allows for even layering and consistent melting or sintering.
Irregular Particles
While more challenging to handle due to poor flowability, irregular particles may offer advantages in certain applications where mechanical interlocking or increased surface area is beneficial.
Aspect Ratio and Morphology
The aspect ratio (length-to-width ratio) and other morphological characteristics can impact how particles stack and bond during printing. Variability in shape can lead to inconsistencies in packing density, affecting the mechanical properties of the final part.
The chemical composition of the powder is also essential for maintaining desired properties such as strength, hardness, and corrosion resistance in the final product.
How to Measure Powders Used in Additive Manufacturing
To achieve the level of quality and reliability required in high-performance applications, researchers and manufacturers are turning to advanced characterisation techniques. Integrating high-resolution particle size analysis, particle shape analysis, and compositional analysis enables more precise control of AM powders.
Tools like the Malvern Morphologi 4 offer advanced solutions for streamlining powder analysis and improving characterisation accuracy.
ASTM Standards for Additive Manufacturing
ASTM standards for additive manufacturing provide guidelines to ensure the quality and reproducibility of materials, processes, and final products.
ATA Scientific offers several technologies that are cited in ISO/ASTM 52907: Additive manufacturing — Feedstock materials — Methods to characterise metal powders. These include:
Malvern Mastersizer 3000+ (ASTM B822/ISO 13320)
ASTM B822-20: Standard test method for particle size distribution of metal powders and related compounds by light scattering. This method covers instrumentation, sampling, dispersion and procedure for the metal powders using laser diffraction. Particle size distribution is reported as volume percent.
The Malvern Mastersizer 3000 Lab delivers world-class laser diffraction for particle size analysis, while Insitec provides particle size measurements in real time. Combined with the Hydro Insight imaging accessory for the Mastersizer 3000+, both particle images and quantitative particle shape data can be assessed.
Laser diffraction systems, such as the Mastersizer 3000+ and Insitec, determine particle size from measurements of the light scattered by the sample material. Larger particles will scatter light at smaller angles and with high intensity, while smaller particles will scatter light at larger angles and with weaker intensity. The diffracted, or scattered, light is captured by detectors placed around the measurement cell at a range of angles. The angular scattering intensity data is then analysed to calculate the size of the particles responsible for creating the scattering pattern, using the Mie theory of light scattering. The particle size is reported as a volume-equivalent sphere diameter.
Insitec, the in-line laser diffraction solution, can handle high throughput where sample preparation, measurements, and analysis can all be automated. As a result, Insitec can be integrated into a production process for real-time analysis and adaptive control. This includes at various points within an atomisation process, or even as part of a sieving or classification operation, to ensure the collected material meets specifications.
The particle size distribution of metal powders is an integral and defining parameter that must be monitored to ensure that batches of material are within specification and can provide the desired in-process behaviour and finished product performance. Laser diffraction is both a fast and efficient method for measuring the particle size distribution of metal powders over a very wide dynamic range in both dry and wet dispersions. Closely matching results between dry and wet measurements of the same sample can be obtained, and comparing the two allows the primary particle size, and indeed the whole size distribution, to be validated.
Phenom Desktop SEM With Integrated EDS Detector(ASTM B215-15 & F1877-16)
ASTM B215-15: Standard Practice for Sampling Metal Powders. This standard covers how a small quantity of metal powder is to be collected such that it is representative of the entire batch of material. The standardised method for obtaining test portions of metal powder is covered considering the possibility of segregation of the metal powder during and after the filling of the containers.
ASTM F1877-16: Standard Practice for Characterisation of Particles. This standard covers procedures for characterising the morphology, quantity, size, and size distribution of particles. The SEM characterisation method is included in this standard. The standard defines and depicts critical morphological parameters including equivalent circle diameter (ECD), aspect ratio (AR), elongation (E), Roundness (R), and Form Factor (FF).
The Phenom desktop SEM with integrated EDS detector for elemental composition offers powerful and rapid image analysis that is also easy to use.
The Thermo Scientific™ Phenom™ ParticleX AM Desktop Scanning Electron Microscope (SEM) provides high-quality SEM imaging plus automated morphological and chemical characterisation of metal powder particles. The system is simple to operate and fast to learn, allowing a wide range of users to do particle and material analysis in-house, effectively eliminating the need for outsourcing. With less wait time, industries can improve production yield and bring products to market faster.
While SEM can gather size-distribution data consistent with laser diffraction, the power of EM analysis is the additional information collected beyond the average diameter. Morphological data acquired by the Phenom SEM allows the classification and sorting of individual particles.
As seen in Figure 1, feed powder particles were categorised as either spherical particles, particles with satellite(s), or deformed/agglomerated particles. These classification rules were then used to sort between the three types of morphologies during automated runs.
Figure 1. Spherical, Satellite, and Deformed Metal Powder Particles.
Phenom ParticleX AM Desktop SEM can automatically identify impurities, obtain their basic characteristics, and log their location. With integrated particle inspector software, users can relocate particles of interest, capture additional detail, and create reports containing images, parameters, and the composition of individual particles. This powerful program also provides an offline tabulated view of every particle, freeing up the instrument for continued testing.
The Phenom ParticleX AM Desktop SEM is a multi-purpose desktop SEM solution designed to deliver automated and accurate analysis on feed powders, identifying potential problems before a single component is created.
Automated Morphologi 4 Static Image Analysis System (ASTM F3571-22)
ASTM F3571-22: Standard guide for additive manufacturing – Feedstock – Particle shape image analysis by optical photography to identify and quantify the agglomerates/satellites in metal powder feedstock. This method covers both static and dynamic image analysis and provides guidance on measurement procedures. It describes how to use particle shape parameters to identify and quantify the proportion of agglomerates/satellites and other non-spherical powder particles in a batch.
The automated Morphologi 4 static image analysis system provides a detailed description of the particles’ morphological properties.
The Malvern Panalytical Morphologi 4 system is an automated static image analysis system that provides statistically relevant particle size and particle shape information, enabling a greater understanding of both sample and process. Through the automated imaging of tens to hundreds of thousands of particles, the Morphologi 4 delivers both qualitative and quantitative analysis of a powder sample. This is advantageous when considering other popular imaging techniques such as Scanning Electron Microscopy (SEM), where typically a low number of images are analysed and is more suited as a qualitative technique.
With long build times per unit, the cost of failure in additive layer manufacture is high. The quality of the powder bed is a controlling factor in the quality of the part in build. In turn, this is controlled by the size and shape of particles of the metal powder. By characterising these properties, it may be possible to forecast when failure might occur and therefore refresh the powder supply before this happens. Automated image analysis is one such solution that can be used to characterise hundreds of thousands of particles to give high-quality and statistically relevant morphological information. This single technique combines the quantitative and qualitative benefits of two other commonly used techniques in this application: dynamic imaging and SEM.
Freeman Technology FT4 Powder Rheometer
ASTM has released three standard test methods that strongly affirm the FT4 as the most trusted tool for the characterisation of powder flow properties. The newly published documents describe the procedures followed by the FT4 standard tests:
ASTM D8328: Standard test method for dynamic testing of powders using the Freeman Technology FT4 Powder Rheometer.
ASTM D8327: Standard test method for measuring the permeability of powders as a function of consolidation using the Freeman Technology FT4 Powder Rheometer.
ASTM D7891: Standard test method for shear testing of powders using the Freeman Technology FT4 Powder Rheometer shear cell.
The bulk properties of powders, notably flowability but also packing behaviour—a critical characteristic for AM—are influenced by the properties of the constituent particles but not predictable from them. The quantification of bulk powder properties therefore relies on measurement. The FT4 Powder Rheometer from Freeman Technology (a Micromeritics company) measures dynamic, shear, and bulk powder properties. By applying all three bulk powder testing techniques, users can generate the information needed to securely differentiate powder samples in a relevant way and identify poor performers. This is a valuable capability that enhances the efficiency of many operations.
Micromeritics AccuPyc Pycnometer
ASTM B923: Metal powder skeletal density by Helium or Nitrogen Pycnometry. This method describes the basic procedure for performing an apparent density measurement on metal powders using helium pycnometry. The performance of many sintered or cast metal structures may be predicted from the skeletal density of the starting metal powder, for all or a portion of the finished piece.
There are a number of important density parameters that affect the sintering kinetics of the powder bed and the porosity and mechanical properties of the final product. Two good examples are the apparent density, describing the density of a porous material excluding any open pores, and the tap density, which is a measure of how well the powder particles pack together.
These characteristics can be studied using the Micromeritics Accupyc Advanced Gas Pycnometer helium pycnometer and GeoPyc envelope/tap density analyser. These instruments are non-destructive and are also able to show the total porosity of the metal powder when used together.
With advances in powder characterisation, Australian industries can continue to push the boundaries of additive manufacturing, producing complex, high-performance components that meet stringent quality standards. Emerging innovations, such as breakthroughs in battery technology, also align with the rapid growth of additive manufacturing technologies.
As AM technology evolves, the demand for precise powder characterisation will only grow, with researchers and manufacturers striving to enhance powder consistency, quality, and application-specific performance. By investing in state-of-the-art characterisation tools to understand and optimise key properties like particle size, shape, and composition, industries that adopt AM can achieve the accuracy, durability, and reliability required.
To learn more about these technologies or to book a demo of the Mastersizer 3000+, Phenom desktop SEM, Morphologi 4 or any other system, Contact Us.
References:
Thermo Fisher Scientific. Particle Analysis with the Phenom ParticleX AM Desktop SEM. Application Note. Thermo Fisher Scientific. Accessed from https://www.thermofisher.com/
ATA Scientific has been appointed as the exclusive distributor for EXODUS BIO in Australia and New Zealand, expanding access to pioneering technology for automated exosome isolation.
This partnership will bring advanced solutions to researchers focused on extracellular vesicle studies, enabling more efficient and reliable sample preparation for applications in diagnostics, drug delivery, and regenerative medicine.
EXODUS BIO is a leading company specialising in upstream exosome tools, leveraging innovative membrane separation technologies to address the industry’s challenges related to automated, standardised, and scalable exosomal preparation. Since its commercialisation in 2021, the automatic exosome isolation system known as EXODUS has garnered recognition and adoption from numerous prestigious universities, research institutions, and pharmaceutical companies globally, including the National Institute of Environmental Health Sciences, Harvard Medical School, and MD Anderson Cancer Center. Looking ahead, EXODUS BIO plans to collaborate closely with ATA Scientific across various domains such as product development and marketing to deliver customers enhanced and comprehensive professional services in exosome purification technology.
EXODUS BIO has gained recognition for its innovative, fully automated exosome isolation system, delivering high-purity exosomes and overcoming obstacles of traditional methods like ultracentrifugation, which can be labour-intensive and produce inconsistent yields. With the Exodus automated system, laboratories can process a wide range of biological fluids with increased reproducibility, enabling downstream analysis without compromising exosome quality.
For an in-depth look at the latest advancements in extracellular vesicle research, download the Nature Methods paper, Chen, Y., Zhu, Q., Cheng, L. et al. Exosome detection via the ultrafast-isolation system: EXODUS. Nat Methods18, 212–218 (2021). https://doi.org/10.1038/s41592-020-01034-x
ATA Scientific’s established presence in the scientific community and its commitment to supporting advanced analytical solutions makes it an ideal partner to introduce EXODUS BIO’s technology across Australia and New Zealand. “We are excited to represent Exodus-Bio in this region and provide local researchers with access to the most advanced exosome isolation technology. This aligns with our commitment to support local scientific research and innovative scientific solutions”.
With this partnership, ATA Scientific aims to equip academic, clinical, and biotech laboratories with tools that support the growing interest in extracellular vesicle research. The collaboration will facilitate workshops, technical support, and training sessions to help scientists optimise the Exodus-Bio system and enhance the impact of their research on exosome biology.
The EXODUS automatic exosome isolation system represents an advanced technological approach for laboratories engaged in extracellular vesicle (EV) research, particularly those focused on exosomes. Exosomes, nanometer-scale EVs with key roles in cell-cell communication, have gained prominence due to their potential as biomarkers for disease diagnostics and as vehicles for therapeutic delivery. Yet, traditional methods for exosome isolation—such as ultracentrifugation, precipitation, and size-exclusion chromatography—pose challenges, including low yield, variable purity, labour-intensive, and susceptibility to sample degradation which limits reproducibility and scalability.
The EXODUS automatic exosome isolation system minimises manual handling, reducing variability and enabling consistent, high-purity yields across a range of biological fluids, including serum, plasma, urine, and cell culture media. Such precision facilitates the preservation of exosomal structural integrity and bioactive molecules, ensuring reliability in downstream applications, including molecular profiling and drug delivery studies.
EXODUS has been developed using a dual-membrane nanofiltration system that integrates periodic negative pressure oscillation (NPO) and double-coupled ultrasonic harmonic oscillations (HO). The exosomes are precisely intercepted by nanoporous membrane, while free nucleic acid and protein impurities are removed from the sample, resulting in the efficient purification and enrichment of exosomes.
The EXODUS system is well-suited for labs aiming to scale up exosome research while maintaining rigorous standards in quality and reproducibility. EXODUS eliminates challenges associated with traditional ultracentrifugation, making exosome isolation more accessible and efficient. Researchers adopting the EXODUS system can expect enhanced workflow efficiency and the capacity to drive new discoveries in the rapidly expanding field of EV research.
Reference:
Chen, Y., Zhu, Q., Cheng, L. et al. Exosome detection via the ultrafast-isolation system: EXODUS. Nat Methods18, 212–218 (2021). https://doi.org/10.1038/s41592-020-01034-x
We are helping to Build Better Batteries during development and manufacturing processes.
The Global Shift Towards Renewable Energy
Increasingly the world is experiencing more frequent and intense extreme weather events which are already impacting every region on Earth. At the COP28 United Nations climate talks in December 2023, governments from nearly 200 countries agreed to the transition away from technologies that use fossil fuels, the primary cause of the climate crisis.
Key Challenges:
Rising extreme weather events
Need for fossil fuel transition
Growing demand for clean energy technologies
While fossil fuel technology is the major contributor to climate change, moving to new and more efficient renewable technologies can help us reduce net emissions and create a more sustainable world.
In power generation, transport, heating, cooking and industrial processes like steel and cement manufacturing, we have new technology needed to replace fossil fuels. In fact, surging market demand for clean energy technologies – wind, solar, and electric cars – is now displacing polluting technologies, such as coal-fired power and combustion engine vehicles, on a global scale. Beyond power generation the need for energy storage is undeniable.
Australian Battery Development Landscape
Current Research Developments
Batteries will play a major role in the world’s decarbonisation journey, and Australia is very well placed for this opportunity given its vast mineral reserves (e.g. lithium, nickel, copper and cobalt) and access to innovative our University’s research and development. Australian researchers at the University of Wollongong have been working with; Edge Functionalised Graphene,’ which they say could unlock cheaper and better-performing lithium-ion batteries.
The lithium salt currently used in lithium-ion batteries is lithium hexafluorophosphate, which poses a safety risk. Researchers are developing the use of fluoroborate salts, which are showing promise for being much safer. Universities within Australia are working with industry on research and development of products. Leveraging that research with strong manufacturing cooperation would allow Australia to develop world-leading products that could create huge benefits for both our economy and the health of our planet.
Dr. Adam Best, Principal Research Scientist at CSIRO, recently delivered an insightful talk on advancing lithium-ion (Li-ion) batteries and making them more sustainable. As one of the world’s largest multidisciplinary science and technology organisations, CSIRO is tackling some of the greatest challenges of our time, including our transition to net-zero emissions. Dr. Best highlighted the rapidly growing global demand for batteries driven by their essential roles in electric vehicles (EVs), stationary energy storage, and everyday devices like mobile phones. Meeting this demand while transitioning to renewable energy presents a significant challenge, particularly in ensuring a reliable supply of critical minerals such as graphite, nickel, cobalt, lithium, aluminum, and copper.
Australia’s Role in the Energy Transition
As a global leader in solar energy adoption, Australia is uniquely positioned with its abundant mineral reserves. For example: Nickel (Ni) and Cobalt (Co): Found in laterite deposits in Australia, both minerals are critical for battery cathodes. Graphite: Essential for anodes, it is commonly synthesized from petroleum-derived coke, a process requiring significant energy. However, using naturally occurring graphite reduces energy requirements, making it a more sustainable alternative.
The Recycling Imperative
To meet the growing demand, analysts estimate that approximately 400 new mines will be required by 2030. However, with mine commissioning taking up to 20 years, there simply isn’t enough time. Recycling will play a pivotal role in addressing this challenge. Current recycling methods include: Pyrometallurgy: Involves burning off carbon, resulting in CO₂ emissions, making it less environmentally friendly. Hydrometallurgy: A more efficient process that uses chemical solutions to recover materials. Direct Recycling: The most sustainable option, this method involves disassembling used cells, recovering the cathode, anode, and electrolyte, and remanufacturing the battery.
Exploring Next-Generation Battery Technologies
Beyond Li-ion batteries, CSIRO is advancing research into innovative energy storage technologies, including: Eel Battery: Based on reverse electrodialysis; Thermal and Atomic Batteries: Harnessing novel energy storage mechanisms; Moisture Electric Generators and Nitrogen Batteries; Metal-Air Batteries (e.g., Li-O₂): High-energy systems using gel polymer electrodes; and Quantum Batteries: Cutting-edge energy storage solutions with potential for transformative applications.
Sustainability in Focus
As the world accelerates towards electrification, sustainable battery production is critical. Reducing waste, energy consumption, and water usage during production will ensure we can meet growing demand while minimizing environmental impacts. CSIRO’s work in Li-ion batteries and beyond underscores the importance of balancing technological advancements with sustainability. Dr. Best’s presentation serves as a powerful reminder: batteries are not just enablers of renewable energy—they must themselves be part of a sustainable future.
The Future of Battery Technology
Sodium-Ion Battery Innovation
The move to renewable energy and storage to power our cars, homes, electronic devices, and everything we rely on for our daily lives, is dependent not only on our ability to build batteries that are cheaper, safer and more efficient but also to build them at scale.
Key advantages:
Cost-effective alternative
Environmental sustainability
Enhanced safety features
Manufacturing compatibility
While lithium-ion batteries have dominated the energy storage landscape for years, issues like limited lithium resources, rising costs and environmental concerns have led researchers and companies to explore sodium ion batteries as a promising alternative.
Lithium-ion vs. Sodium-ion Batteries: Key Differences
Feature
Lithium-ion Battery
Sodium-ion Battery
Applications
EVs, mobile devices
Grid storage, scooters, buses
Cost
Higher
Lower
Resource Availability
Limited (Lithium)
Abundant (Sodium)
Energy Density
Higher (Compact)
Lower (Bulkier)
Environmental Impact
Higher (Heavy metals used)
Lower (Easier to recycle)
Safety
Prone to overheating
Less prone to overheating
Researchers at the University of Wollongong (UOW) Institute for Superconducting and Electronic Materials (ISEM) are continuing to develop new materials and processing techniques that will enable a major step forward in the development of sodium-ion batteries to be used as a viable alternative for large-scale storage where the size of the battery is less of an issue.
Material Properties Optimization
Are Sodium-ion batteries a good choice?
Sodium-based materials are emerging as a significant trend in the battery market primarily due to the limitations of traditional lithium-ion batteries and the growing demand for alternatives. Although sodium-ion batteries tend to have a lower energy density meaning they are bulkier and heavier compared to Li-ion batteries which can store more energy for a given volume or weight, sodium is far more abundant and cheaper to extract.
Sodium-ion batteries don’t require heavy metals to produce – making them easier to recycle and having less impact on the environment. Sodium ion batteries are less prone to overheating offering safety advantages over lithium-ion batteries. They are ideal for stationary applications such as a grid-scale power station and modes of transport that aren’t required to travel long distances, such as electric scooters or electric buses.
Given the significant benefits Sodium-ion batteries offer and the fact that they work in a way similar to Li-ion batteries, they are a simple alternative to integrate into existing battery technologies and manufacturing processes.
Optimised battery material properties
Particle Shape Importance
Particle shape plays a critical role in the performance and manufacturing of sodium-based batteries as well as impacting several key factors that influence the efficiency, safety and durability of batteries.
Spherical particles provide a more controlled and consistent surface area often leading to better packing density and uniformity. Irregular particles might offer more surface area but can result in uneven reactions and inconsistent battery performance. Spherical particles offer smoother and more predictable pathways for ion transport improving the batter’s efficiency, while irregularly shaped particles can create longer pathways which might slow down ion transport and reduce the charge and discharge rate.
Spherical particles provide a more controlled and consistent surface area, often analyzed using SEM and TEM techniques, which reveal intricate details about particle morphology and structure.
Impact of Particle Shape on Battery Performance and Manufacturing
Particle Shape
Impact on Manufacturing
Impact on Battery Performance
Well-Defined Shapes
Creates thicker, uniform electrodes
Retains conductivity and enhances energy density
Spherical
Easier to process and coat
Improves ion transport and efficiency
Irregular
Harder to achieve uniform distribution
May slow ion transport, reducing charge rates
Uniform and well-defined shapes such as spheres are generally easier to process mix and coat during the production of battery electrodes. Highly round particles can help create thicker more uniform electrodes that retain good conductivity and ion transport characteristics, while irregular particles may limit the electrode thickness due to poor packing and uneven distribution reducing the achievable energy density.
In the sodium-based battery industry controlling the particle shape of powders is crucial for maximising battery performance efficiency and durability.
Advanced Analysis Technologies
Morphologi 4-ID for automated particle shape analysis
The Malvern Morphologi 4 combines the power of optical microscopy with sophisticated software algorithms to analyse and quantify particle shape (or size). Unlike traditional microscopy, which requires manual operation and analysis, automated optical imaging can capture the shape, size, texture, and distribution of thousands of particles at once.
Using Morphologi 4’s fully automated image analysis capabilities, users can measure circularity, elongation/aspect ratio, circular Equivalent (CE) diameter, transparency and more for particles as small as 0.5 μm, and sample sizes from 10,000 to 500,000 particles.
In addition, with the Morphologi 4-ID, these automated static imaging capabilities can be combined with Raman spectroscopy, enabling users to simultaneously measure particle size, shape, and chemical identity on one platform.
With the demand for batteries increasing rapidly, more and more manufacturers will need automated optical imaging in their quality-control toolbox. Instruments like the Morphologi 4 can help solve this often-overlooked piece of the battery-manufacturing puzzle.
Importance of particle size analysis
Ensuring that the particles used in battery materials are correctly sized is essential for problem-free manufacturing and battery performance. From optimising the flow of battery slurries, the packing density and porosity of electrode coatings, and charge rate capacity and cycling durability of battery cells – it is important to have an accurate and reliable measurement of the material particle size distribution. See the webinar for more information.
Mastersizer 3000+ for Particle Size Distribution
Key Features:
User-friendly interface
SOP Architect capability
Real-time measurement optimisation
Data Quality Guidance Software
Building on the success of our Mastersizer 3000 laser diffraction instrument, the new Mastersizer 3000+ with its added features, is ideal for customers that require access to near-instantaneous insights into particulate mixtures for their battery research and production operations. The user-friendly interface takes the guesswork out of particle size distribution measurement.
By passing a laser beam through a dispersed particulate sample, the Mastersizer 3000+ laser diffraction system rapidly determines the size and proportion of the particulates based on Mie’s theory of light scattering. This enables users to optimise the properties of battery slurries, electrode coatings, and battery cells quickly and reliably, even in a production environment – and the Mastersizer 3000+ makes this easier than ever.
The SOP Architect feature guides even first-time users through the method development process, while the Measurement Manager helps users optimise measurement conditions in real time for particles from 10nm to 3.5mm in size. When users receive their results, they can consult Mastersizer 3000+’s Data Quality Guidance software to identify potential data quality issues and receive suggestions for solutions – just like having an expert there available to assist with the measurement process and data interpretation at all times.
Comparison of Morphologi 4-ID and Mastersizer 3000+ Features
Feature
Morphologi 4-ID
Mastersizer 3000+
Software Features
Automated image analysis
SOP Architect and Data Quality Guidance
Application
Particle shape and chemical identity
Particle size distribution
Technology
Optical microscopy + Raman spectroscopy
Laser diffraction
Particle Size Range
0.5 µm and up
10 nm to 3.5 mm
Would you like to learn more about our new battery technology and battery analysis solutions? Contact our team for expert consultation.
To learn more about these innovations and discover even more features of the Morphologi 4ID and Mastersizer 3000+, Contact us.
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