Photocentric’s latest technology innovation, JENI – a fully automated digital mass manufacturing platform, will be utilized, alongside use of newly developed bio-based, eco-friendly materials.

An industry-academia collaboration to advance sustainable bioprocessing through innovative materials for additive manufacturing, also known as 3D printing, has been announced by Innovate UK (IUK), as part of the “Sustainable Medicines Manufacturing Innovation: Collaborative R&D Fund.”

Project Nexus — a collaboration between Photocentric, Sartorius, Metamorphic, CPI, the University of Sheffield, and Imperial College London, is embarking on the development of new sustainable materials for application in single-use bioprocessing equipment such as bioreactors.

“The goals at the heart of the Nexus project go beyond simply enabling us to unlock the applications of today. They also allow us to realize 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,” says Jeremy Pullin, head of AM and manufacturing technology of Sartorius.

Single-use technologies (SUTs) offer numerous benefits, including faster setup and flexible process configurations, while significantly contributing to the reduction of resources like water, electricity, and caustic chemical usage. Although their waste contributes only about 0.002 percent to global plastic waste, this project aims to further enhance the advantages of SUTs by introducing sustainable material formulations for additive manufacturing.

CAD rendering of a 3D printed media contact device that is used to continuously monitor media within a bioreactor via spectroscopy.

Through £1.9 million ($2.4 million) of funding via the Innovate UK (IUK) – Sustainable Medicines Manufacturing Innovation: Collaborative R&D program, Project Nexus brings together extensive expertise across advanced manufacturing automation, digital design, and optimization, as well as material innovation and bioprocessing, to pioneer the future of AM of bioreactors at scale. The project aims to offer a greener alternative to SU bioreactors with enhanced circularity and end-of-life pathways, all while retaining the flexibility of disposable systems.

“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,” says Paul Holt, founder and managing director of Photocentric.

By utilizing 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.

“We’re excited to contribute our expertise in material innovation to Project Nexus. By developing a highperformance, bio-based resin tailored for bioreactors, we are enabling a more sustainable future for biopharmaceutical manufacturing,” says Tony Jackson, director of formulation at CPI. “Our focus on circularity and end-of-life solutions ensures that this project not only advances technological capabilities but also drives meaningful progress toward net zero goals. We look forward to collaborating with our partners to redefine the role of additive manufacturing in the sector.”

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.

“We’re excited to contribute the AMRC’s wealth of experience in sustainable design engineering to Project Nexus,” says Jose Casamayor Alarco, technical fellow at University of Sheffield AMRC. “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 is fully established and set to deliver over the next 24 months. Further updates will be disseminated as this project progresses.

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See an infographic showing how single-use technologies improve healthcare outcomes and reduce environmental impacts.

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Single-Use Technologies (SUTs) Improve Healthcare Outcomes and Reduce Environmental Impacts

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    Medical Design Briefs Magazine

    This article first appeared in the May, 2025 issue of Medical Design Briefs Magazine (Vol. 15 No. 5).

    Read more articles from this issue here.

    Read more articles from the archives here.

    Overview

    The document discusses the benefits and impacts of Single-Use Technologies (SUTs) in the healthcare sector, emphasizing their role in improving healthcare outcomes while minimizing environmental effects. SUTs are highlighted as a significant advancement in biomanufacturing, contributing to the United Nations Sustainable Development Goals.

    Key advantages of SUTs include substantial resource conservation. On average, SUTs result in a 95% reduction in the use of caustic chemicals, an 87% decrease in water consumption, and a 30% reduction in electricity usage. This efficiency leads to smaller facility footprints and less environmental strain. The document also notes that SUTs facilitate quicker development and manufacturing of medications and vaccines, thanks to their flexible process configurations and faster setup times.

    In terms of waste management, SUTs generate relatively low levels of plastic waste annually, estimated between 4,500 to 11,700 tons in biomanufacturing, compared to a staggering 442,300,000 tons of total worldwide plastic waste. This positions SUTs as a more sustainable option within the broader context of plastic use.

    The document emphasizes ongoing innovation in SUTs, with emerging bioprocessing technologies aimed at enhancing efficiency and yield, decarbonizing processes, and reducing material consumption. These advancements are expected to improve logistics and contribute to a more circular supply chain. Additionally, the development and evaluation of bio-based carbon plastics, recycling opportunities, and eco-design guidelines are mentioned as part of the continuous improvement efforts in SUTs.

    It is important to note that while the content discusses the alignment of SUTs with the United Nations Sustainable Development Goals, it clarifies that the publication has not been officially approved by the United Nations and does not reflect its views.

    Overall, the document presents SUTs as a transformative force in the biomanufacturing industry, highlighting their potential to enhance healthcare delivery while addressing environmental challenges. The insights provided underscore the importance of innovation and sustainability in the ongoing evolution of healthcare technologies.