High-throughput and versatile design for multi-layer coating deposition using lab automation through Arduino-controlled devices.

Abstract

Laboratory and experimental scale manufacturing processes are limited by human error (e.g., poor control over motion and personal subjectivity), especially under fatiguing conditions involving precise, repetitive operations, incurring compounding errors. Commercial layer-by-layer (LbL) automation devices are prohibitively high-priced (especially for academic institutions) with limited flexibility in form factor and potentially software-associated constraints/limitations. In this work, a novel automated multi-beaker dip coater was fabricated to facilitate nano cerium oxide/polymer coatings via an LbL dip coating process and the synthesis of nano ceria films via a novel successive ionic layer adsorption and reaction method on a glass substrate. Automation of tasks, such as those mediating the detailed procedures, is essential in producing highly reproducible, consistent products/materials as well as in reducing the time commitments for laboratory researchers. Herein, we detail the construction of a relatively large, yet inexpensive, LbL coating instrument that can operate over 90cm in the horizontal axis, allowing, for example, up to eight 200 ml beakers with accompanying stir plates. The instrument is operated by simple "off-the-shelf" electronics to control the path and timing of the samples with open-source software while providing precision at ±0.01mm. Furthermore, 3D-printed components were used to maximize the number of substrates that could be coated simultaneously, further improving the sample production rate and reducing waste. Further possibilities for automation beyond the detailed device are provided and discussed, including software interfaces, physical control methods, and sensors for data collection/analysis or for triggers of automated tasks.