Nikolaj Eusebius Jakobsen | Novo Nordisk: Can we print robust electrical sensors directly onto 3D-printed aseptic nozzles to control micro-volume liquid filling?
06:24 - 08:23
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Summary of the clip:
How can we leverage micro-electrode integration directly onto fluidic delivery needles to achieve real-time, robust fluid detection?
In the development of smart drug delivery devices, integrating sensing capabilities directly onto the needle structure represents a significant leap forward. By utilizing the fluid itself to close an electrical circuit, we can transition from passive delivery channels to active, closed-loop diagnostic systems. This approach relies on detecting the sharp transition in electrical properties that occurs when a conductive liquid bridges the gap between two integrated micro-electrodes.
While both capacitive and resistive sensing modalities can detect fluid contact, resistive measurement offers superior reliability for clinical applications. Capacitive configurations, which measure changes in capacitance upon fluid contact, remain highly susceptible to parasitic capacitance and environmental electromagnetic interference. In contrast, direct resistivity measurement between two localized electrodes provides a highly robust, binary-like signal that is virtually immune to external field fluctuations.
To validate this architecture, functional prototypes were fabricated using 3D-printed needle substrates integrated with fine conductive wiring and dedicated control circuitry. In a multi-needle array configuration, each nozzle operates with an independent solenoid valve managed by a central printed circuit board. The moment the fluid front contacts the dual-electrode sensor on a given needle, the resulting resistivity drop triggers an immediate feedback signal, prompting the solenoid to close and precisely terminate the localized flow.
In this short video, you can learn:
* The technical trade-offs between capacitive and resistive sensing modalities for in-line fluid detection.
* How 3D-printed needle substrates can be instrumented with micro-electrodes to create active fluidic sensors.
* The integration of sensor-driven feedback loops with solenoid valves for automated, localized flow control.
π **Clip Abstract** The speaker demonstrates how to integrate resistive and capacitive sensors onto 3D-printed needles to detect fluid contact. He explains that resistive sensing is more robust than capacitive sensing against external interference, and shows a prototype where sensor feedback triggers a solenoid valve to shut off fluid flow.
π€ Speaker: Nikolaj Eusebius Jakobsen
π’ Company: Novo Nordisk
π
Event: The Future of Electronics RESHAPED 2023 Berlin
π Location: Estrel Congress Centre, Berlin, Germany, Europe
π Learn more at the next TechBlick event: https://www.techblick.com
#ResistiveLevelSensing, #3DPrintedSensors, #SmartNeedles, #PrintedElectronics, #AsepticManufacturing, #MicroVolumeFilling
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04:56 - 06:02
How can you scale pharmaceutical filling speeds up to 12x without creating a mechanical integration nightmare?
How can fluidic manifold architectures and integrated sensor arrays overcome the throughput bottlenecks of traditional multi-line pharmaceutical filling systems?
High-throughput pharmaceutical dispensing is severely constrained by the physical footprint and complexity of dedicated fluidic lines. In conventional filling systems, scaling throughput requires a linear increase in both delivery lines and dispensing needles. This proportional scaling introduces prohibitive mechanical complexity, making system sanitization, line routing, and product changeover highly inefficient.
Transitioning to a centralized manifold architecture allows a single primary fluid feed to distribute media across a high-density array of independently controlled dispensing needles. By decoupling the feed line count from the needle count, production lines can scale up to dozens or even over a hundred dispensing points. This consolidated manifold design dramatically accelerates filling velocity while simplifying the physical routing of the fluidic path.
To successfully implement these high-density manifold systems, advanced process control must be integrated directly at the point of dispensing. Operating a massive array of needles from a single manifold requires precise, localized regulation of flow rates and volumes. Leveraging novel sensor fabrication techniques, such as printed electronics and integrated microfluidic sensors, is essential to monitor and control each dispensing channel individually without adding bulk.
In this short video, you can learn:
* The mechanical and operational limitations of scaling traditional multi-line filling systems.
* The design principles of high-density manifold architectures for multi-needle dispensing.
* The critical role of novel sensor manufacturing in enabling individual channel control.
π **Clip Abstract** The speaker discusses the limitations of scaling up pharmaceutical filling systems using individual lines for each needle, which complicates batch changeovers. He proposes a centralized manifold system capable of controlling up to 120 needles individually from a single line to dramatically increase filling speeds.
π€ Speaker: Nikolaj Eusebius Jakobsen
π’ Company: Novo Nordisk
π
Event: The Future of Electronics RESHAPED 2023 Berlin
π Location: Estrel Congress Centre, Berlin, Germany, Europe
π Learn more at the next TechBlick event: https://www.techblick.com
#MultiNeedleManifold, #SolenoidValveControl, #ParallelFluidicFilling, #AsepticCartridgeFilling, #PharmaFillFinish, #PrecisionDispensing
12:59 - 14:22
How do strict Annex 1 "second air" contamination regulations force a complete redesign of pharmaceutical sensor placement?
How do strict Annex 1 "second air" contamination regulations force a complete redesign of pharmaceutical sensor placement?
The European Union's updated Annex 1 regulations place stringent limits on "second air" contamination within aseptic manufacturing environments. Under these rules, any airflow touching a non-sterile sensor before passing over an open drug cartridge is strictly prohibited, rendering traditional external optical level-sensing systems non-compliant if positioned too close.
Since many sensitive electronic sensors cannot survive the aggressive heat, steam, and chemical sterilization processes required for aseptic zones, they must be kept far away from the active filling area. This physical separation dramatically limits measurement accuracy and prevents clean, close-up monitoring of high-speed filling lines.
The breakthrough solution is to integrate sterilized, 3D-printed electrode arrays directly onto the outer surface of the filling needle itself. Because the needle is already engineered to withstand aseptic sterilization, the sensor is inherently compliant with Annex 1, eliminating non-sterile air currents near open cartridges.
In this short video, you can learn:
* The regulatory impact of Annex 1 "second air" guidelines on aseptic pharmaceutical packaging.
* Why traditional electronic and optical sensors fail the rigorous physical sterilization requirements of cleanrooms.
* How printing 3D electrodes directly on sterilized needles bypasses contamination risks while keeping sensors close to the product.
π **Clip Abstract** Annex 1 regulations restrict unsterilized sensor equipment from being positioned over open drug cartridges due to "second air" contamination risks. Integrating printed 3D electrodes directly onto the sterilizable needle itself resolves this compliance issue, allowing high-precision sensing right at the fill point.
#Annex1Compliance, #3DPrintedElectrodes, #SmartNeedles, #SecondAirContamination, #PrintedElectronics, #AsepticManufacturing