Single-use container with 3D printed functional element, printing method therefor and assembly
A method for producing a single-use container, particularly a single-use bioreactor, an assembly system, and a single-use container particularly a single-use bag such as a single-use bioreactor comprising: a base material; and at least one functional element being at least partially connected with the base material, wherein the functional element is obtained by a three dimensional printing technique from at least one printable material, wherein the printable material is heated during the three dimensional printing thereby at least partly connecting the printed functional element to the base material.
1 . A single-use container for use as a bioreactor, comprising:
a base material being a flexible material selected from the group consisting of a two-dimensional film, a stock sheet, a pre-cut bag, a pre-made bag, and a wall element of a bag or container; and
at least one functional element being directly and permanently connected to the base material,
wherein the at least one functional element comprises at least one printable material that is connected to the base material by heating the at least one printable material and simultaneously heating at least a portion of the base material during three-dimensional printing of the at least one printable material onto a surface of the base material, and
wherein the at least one functional element comprises a port that is fused to the base material around an excess portion of the base material, and
wherein the base material comprises an opening disposed within an interior region of the port, the opening being formed by removal of the excess portion of the base material after the port is connected.
2 . The single-use container according to claim 1 , wherein the at least one functional element further comprises at least one out of the following:
a flange, an inlet and/or outlet point, a sensor holder, a sensor or a part of a sensor, a window or a window frame, a tube holder, a handle, and a connector.
3 . The single-use container according to claim 1 , wherein the at least one functional element further comprises at least one out of the following:
a label, a substantially three-dimensional text, and a reference marker or fiducial.
4 . The single-use container according to claim 1 , wherein the at least one functional element further comprises a stabilizing element, stiffening element, and/or a reinforcement element.
5 . The single-use container according to claim 1 , wherein the at least one functional element further comprises an electronic component.
6 . The single-use container according to claim 1 , wherein the base material and/or the at least one functional element comprises at least one of: PE, EVA, ABS, PC, PMMA, PLA, PES, PSU, POM, PEEK, PEI, PPO, PP, PET, PS, PA, PTFE, PU, TPE, silicone, fluoropolymers, copolyesters, acrylic.
7 . The single-use container according to claim 1 , wherein the at least one printable material is printed by a three dimensional printing technique comprising a fused filament fabrication, a drop-by-drop application of the printable material, and/or a layer-by-layer application of the printable material.
8 . The single-use container according to claim 7 , wherein the three dimensional printing technique further comprises printing from one or more of nanoparticle ink, spraying atomized metal, melting a metal powder, and aerosol jetting an electronic component.
9 . A method of producing a single-use container by producing at least one functional element and connecting the at least one functional element with a base material of the container, comprising the steps of:
providing the base material, the base material being a flexible material selected from the group consisting of a two-dimensional film, a stock sheet, a pre-cut bag, a pre-made bag, and a wall element of a bag or container;
three-dimensional printing of the at least one functional element from a printable material on a surface of the base material; and
connecting at least a portion of the at least one functional element with at least a portion of the base material by supplying heat to the printable material and the base material simultaneously to and/or prior to at least an interval of the step of three dimensional printing, wherein the at least one functional element comprises a port that is fused to the base material around an excess portion of the base material, and
removing the excess portion after the port is fused to the base material to define an opening within an interior region of the port.
10 . The method according to claim 9 , wherein the step of supplying heat comprises the step of pre-heating the base material.
11 . The method according to claim 9 , wherein the step of three dimensional printing of the at least one functional element comprises a step of printing from printable material, at least one of: acrylics, EVA, ABS, PC, PE, PMMA, PLA, PES, POM, PEEK, PEI, PP, PS, PTFE.
12 . The method according to claim 9 , wherein the step of three dimensional printing comprises the step of printing from a nanoparticle ink and/or spraying atomized metal and/or melting a metal powder and/or aerosol jetting an electronic component.
13 . The method according to claim 9 , further comprising the step of removing a portion of the base material and/or removing an excess portion of the at least one functional element.
14 . The method according to claim 9 , wherein the three-dimensional printing of the at least one functional element comprises a fused filament fabrication, a drop-by-drop application of the printable material, and/or a layer-by-layer application of the printable material.
15 . The method according to claim 9 , further comprising
removing excess material from either the at least one functional element and/or the base material; and
at least partly recycling the excess material being removed by reusing it in the three dimensional printing step and/or in a step of manufacturing the base material.