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суббота, 10 апреля 2021 г.

10 Breakthrough Technologies 2021. 1. Messenger RNA vaccines

the Editors

This list marks 20 years since we began compiling an annual selection of the year’s most important technologies. Some, such as mRNA vaccines, are already changing our lives, while others are still a few years off. Below, you’ll find a brief description along with a link to a feature article that probes each technology in detail. We hope you’ll enjoy and explore—taken together, we believe this list represents a glimpse into our collective future.

Messenger RNA vaccines


 
SELMAN DESIGN

We got very lucky. The two most effective vaccines against the coronavirus are based on messenger RNA, a technology that has been in the works for 20 years. When the covid-19 pandemic began last January, scientists at several biotech companies were quick to turn to mRNA as a way to create potential vaccines; in late December 2020, at a time when more than 1.5 million had died from covid-19 worldwide, the vaccines were approved in the US, marking the beginning of the end of the pandemic.

The new covid vaccines are based on a technology never before used in therapeutics, and it could transform medicine, leading to vaccines against various infectious diseases, including malaria. And if this coronavirus keeps mutating, mRNA vaccines can be easily and quickly modified. Messenger RNA also holds great promise as the basis for cheap gene fixes to sickle-cell disease and HIV. Also in the works: using mRNA to help the body fight off cancers. Antonio Regalado explains the history and medical potential of the exciting new science of messenger RNA.

The next act for messenger RNA could be bigger than covid vaccines

New messenger RNA vaccines to fight the coronavirus are based on a technology that could transform medicine. Next up: sickle cell and HIV.

On December 23, as part of a publicity push to encourage people to get vaccinated against covid-19, the University of Pennsylvania released footage of two researchers who developed the science behind the shots, Katalin Karikó and Drew Weissman, getting their inoculations. The vaccines, icy concoctions of fatty spheres and genetic instructions, used a previously unproven technology based on messenger RNA and had been built and tested in under a year, thanks to discoveries the pair made starting 20 years earlier.

In the silent promotional clip, neither one speaks or smiles as a nurse inserts the hypodermic into their arms. I later asked Weissman, who has been a physician and working scientist since 1987, what he was thinking in that moment. “I always wanted to develop something that helps people,” he told me. “When they stuck that needle in my arm, I said, ‘I think I’ve finally done it.’”

The infection has killed more than 2 million people globally, including some of Weissman’s childhood friends. So far, the US vaccine campaign has relied entirely on shots developed by Moderna Therapeutics of Cambridge, Massachusetts, and BioNTech in Mainz, Germany, in partnership with Pfizer. Both employ Weissman’s discoveries. (Weissman’s lab gets funding from BioNTech, and Karikó now works at the company.)

Unlike traditional vaccines, which use live viruses, dead ones, or bits of the shells that viruses come cloaked in to train the body’s immune system, the new shots use messenger RNA—the short-lived middleman molecule that, in our cells, conveys copies of genes to where they can guide the making of proteins.

The message the mRNA vaccine adds to people’s cells is borrowed from the coronavirus itself—the instructions for the crown-like protein, called spike, that it uses to enter cells. This protein alone can’t make a person sick; instead, it prompts a strong immune response that, in large studies concluded in December, prevented about 95% of covid-19 cases.

Drew Weissman’s work with messenger RNA led to successful covid-19 vaccines.
JUSTIN JAMES MUIR

Beyond potentially ending the pandemic, the vaccine breakthrough is showing how messenger RNA may offer a new approach to building drugs.

In the near future, researchers believe, shots that deliver temporary instructions into cells could lead to vaccines against herpes and malaria, better flu vaccines, and, if the covid-19 germ keeps mutating, updated coronavirus vaccinations, too.

But researchers also see a future well beyond vaccines. They think the technology will permit cheap gene fixes for cancer, sickle-cell disease, and maybe even HIV.

For Weissman, the success of covid vaccines isn’t a surprise but a welcome validation of his life’s work. “We have been working on this for over 20 years,” he says. “We always knew RNA would be a significant therapeutic tool.”

Perfect timing

Despite those two decades of research, though, messenger RNA had never been used in any marketed drug before last year.

Then, in December 2019, the first reports emerged from Wuhan, China, about a scary transmissible pneumonia, most likely some kind of bat virus. Chinese government censors at first sought to cover up the outbreak, but on January 10, 2020, a Shanghai scientist posted the germ’s genetic code online through a contact in Australia. The virus was already moving quickly, jumping onto airplanes and popping up in Hong Kong and Thailand. But the genetic information moved even faster. It arrived in Mainz at the headquarters of BioNTech, and in Cambridge at Moderna, where some researchers got the readout as a Microsoft Word file.

Scientists at Moderna, a biotech specializing in messenger RNA, were able to design a vaccine on paper in 48 hours, 11 days before the US even had its first recorded case. Inside of six weeks, Moderna had chilled doses ready for tests in animals.

Unlike most biotech drugs, RNA is not made in fermenters or living cells—it’s produced inside plastic bags of chemicals and enzymes. Because there’s never been a messenger RNA drug on the market before, there was no factory to commandeer and no supply chain to call on.

When I spoke to Moderna CEO Stéphane Bancel in December, just before the US Food and Drug Administration authorized his company’s vaccine, he was feeling confident about the shot but worried about making enough of it. Moderna had promised to make up to a billion doses during 2021. Imagine, he said, that Henry Ford was rolling the first Model T off the production line, only to be told the world needed a billion of them.

Bancel calls the way covid-19 arrived just as messenger RNA technology was ready an “aberration of history.”

In other words, we got lucky.

Human bioreactors

The first attempt to use synthetic messenger RNA to make an animal produce a protein was in 1990. It worked but a big problem soon arose. The injections made mice sick. “Their fur gets ruffled. They lose weight, stop running around,” says Weissman. Give them a large dose, and they’d die within hours. “We quickly realized that messenger RNA was not usable,” he says.

The culprit was inflammation. Over a few billion years, bacteria, plants, and mammals have all evolved to spot the genetic material from viruses and react to it. Weissman and Karikó’s next step, which “took years,” he says, was to identify how cells were recognizing the foreign RNA.

As they found, cells are packed with sensing molecules that distinguish your RNA from that of a virus. If these molecules see viral genes, they launch a storm of immune molecules called cytokines that hold the virus at bay while your body learns to cope with it. “It takes a week to make an antibody response; what keeps you alive for those seven days is these sensors,” Weissman says. But too strong a flood of cytokines can kill you.

The eureka moment was when the two scientists determined they could avoid the immune reaction by using chemically modified building blocks to make the RNA. It worked. Soon after, in Cambridge, a group of entrepreneurs began setting up Moderna Therapeutics to build on Weissman’s insight.

Vaccines were not their focus. At the company’s founding in 2010, its leaders imagined they might be able to use RNA to replace the injected proteins that make up most of the biotech pharmacopoeia, essentially producing drugs inside the patient’s own cells from an RNA blueprint. “We were asking, could we turn a human into a bioreactor?” says Noubar Afeyan, the company’s cofounder and chairman and the head of Flagship Pioneering, a firm that starts biotech companies.

If so, the company could easily name 20, 30, or even 40 drugs that would be worth replacing. But Moderna was struggling with how to get the messenger RNA to the right cells in the body, and without too many side effects. Its scientists were also learning that administering repeat doses, which would be necessary to replace biotech blockbusters like a clotting factor that’s given monthly, was going to be a problem. “We would find it worked once, then the second time less, and then the third time even lower,” says Afeyan. “That was a problem.”

Moderna pivoted. What kind of drug could you give once and still have a big impact? The answer eventually became obvious: a vaccine. With a vaccine, the initial supply of protein would be enough to train the immune system in ways that could last years, or a lifetime.

A second major question was how to package the delicate RNA molecules, which last for only a couple of minutes if exposed. Weissman says he tried 40 different carriers, including water droplets, sugar, and proteins from salmon sperm. It was like Edison looking for the right filament to make an electric lamp. “Almost anything people published, we tried,” he says. Most promising were nanoparticles made from a mixture of fats. But these were secret commercial inventions and are still the basis of patent disputes. Weissman didn’t get his hands on them until 2014, after half a decade of attempts.

When he finally did, he loved what he saw. “They were better than anything else we had tried,” he says. “It had what you wanted in a drug. High potency, no adverse events.” By 2017, Weissman’s lab had shown how to vaccinate mice and monkeys against the Zika virus using messenger RNA, an effort that soon won funding from BioNTech. Moderna was neck and neck.  It quickly published results of an early human test of a new mRNA influenza vaccine and would initiate a large series of clinical studies involving diseases including Zika.

Pivoting to vaccines did have a drawback for Moderna. Andrew Lo, a professor at MIT’s Laboratory for Financial Engineering, says that most vaccines lose money. The reason is that many shots sell for a “fraction of their economic value.” Governments will pay $100,000 for a cancer drug that adds a month to a person’s life but only want to pay $5 for a vaccine that can protect against an infectious disease for good. Lo calculated that vaccine programs for emerging threats like Zika or Ebola, where outbreaks come and go, would deliver a -66% return on average. “The economic model for vaccines is broken,” he says.

On the other hand, vaccines are more predictable. When Lo’s team analyzed thousands of clinical trials, they found that vaccine programs frequently succeed. Around 40% of vaccine candidates in efficacy tests, called phase 2 clinical trials, proved successful, a rate 10 times that of cancer drugs.

Adding to mRNA vaccines’ chance of success was a lucky break. Injected into the arm, the nanoparticles holding the critical instructions seemed to home in on dendritic cells, the exact cell type whose job is to train the immune system to recognize a virus. What’s more, something about the particles put the immune system on alert. It wasn’t planned, but they were working as what’s called a vaccine adjuvant. “We couldn’t believe the effect,” says Weissman.

Vaccines offered Moderna’s CEO, Bancel, a chance to advance a phalanx of new products. Since every vaccine would use the same nanoparticle carrier, they could be rapidly reprogrammed, as if they were software. (Moderna had even trademarked the name “mRNA OS,” for operating system.) “The way we make mRNA for one vaccine is exactly the same as for another,” he says. “Because mRNA is an information molecule, the difference between our covid vaccine, Zika vaccine, and flu vaccine is only the order of the nucleotides.”

95% effective

Back in March 2020, when the vaccine programs were getting under way, skeptics said messenger RNA was still an unproven technology. Even this magazine said a vaccine would take 18 months, at a minimum—a projection that proved off by a full nine months. “Sometimes things take a long time just because people think it does,” says Afeyan. “That weighs on you as a scientific team. People are saying, ‘Don’t go any faster!’”

The shots from Moderna and BioNTech proved effective by December and were authorized that month in the US. But the record speed was not due only to the novel technology. Another reason was the prevalence of infection. Because so many people were catching covid-19, the studies were able to amass evidence quickly.

Is messenger RNA really a better vaccine? The answer seems to be a resounding yes. There are some side effects, but both shots are about 95% effective (that is, they stop 95 out of 100 cases), a record so far unmatched by other covid-19 vaccines and far better than the performance of flu vaccines. Another injection, made by AstraZeneca using an engineered cold virus, is around 75% effective. A shot developed in China using deactivated covid-19 germs protected only half the people who got it, although it did stop severe disease.

“This could change how we make vaccines from here on out,” says Ron Renaud, the CEO of Translate Bio, a company working with the technology.

The potency of the shots, and the ease with which they can be reprogrammed, mean researchers are already preparing to go after HIV, herpes, infant respiratory virus, and malaria—all diseases for which there’s no successful vaccine. Also on the drawing board: “universal” flu vaccines and what Weissman calls a “pan-coronavirus” shot that could offer basic protection against thousands of pathogens in that category, which have led not only to covid-19 but, before that, to the infection SARS and probably other pandemics throughout history.

“You have to assume we’re going to have more,” Weissman says. “So instead of shutting down the world for a year while you make a new vaccine, we’ll have a vaccine ready to go.”

Facilities of the biopharmaceutical company Lonza in Switzerland and New Hampshire, which are helping to manufacture Moderna’s vaccine.

Last spring, Bancel began petitioning the government to pay for vast manufacturing centers to make messenger RNA. He imagined a megafactory that “companies could use in peacetime” but that could be quickly reoriented to churn out shots during the next pandemic. That would be insurance, he says, against a nightmare scenario of a germ that spreads as fast as covid but has the 50% fatality rate of Ebola. If “governments spend billions on nuclear weapons they hope to never use,” Bancel argued in April, then “we should equip ourselves so this never happens again.”

Later that month, as part of Operation Warp Speed, the US effort to produce the vaccines, Moderna was effectively picked as a national champion to build such centers. The government handed it nearly $500 million to develop its vaccine and expand manufacturing.

Beyond vaccines

After the covid vaccines, some researchers expect Moderna and BioNTech to return to their original plans for the technology, like treating more conventional ailments such as heart attacks, cancer, or rare inherited diseases. But there’s no guarantee of success in that arena.

“Although there are a lot of potential therapeutic applications for synthetic mRNA in principle, in practice the problem of delivering sufficient amounts of mRNA to the right place in the body is going to be a huge and possibly insurmountable challenge in most cases,” says Luigi Warren, a biotech entrepreneur whose research as a postdoc formed the nucleus of Moderna.

There is one application in addition to vaccines, however, where brief exposure to messenger RNA could have effects lasting years, or even a lifetime.

In late 2019, before covid-19, the US National Institutes of Health and the Bill and Melinda Gates Foundation announced they would spend $200 million developing affordable gene therapies for use in sub-Saharan Africa. The top targets: HIV and sickle-cell disease, which are widespread there.

Gates and the NIH didn’t say how they would make such cutting-edge treatments cheap and easy to use, but Weissman told me that the plan may depend on using messenger RNA to add instructions for gene-editing tools like CRISPR to a person’s body, making permanent changes to the genome. Think of mass vaccination campaigns, says Weissman, except with gene editing to correct inherited disease.

Right now, gene therapy is complex and expensive. Since 2017, several types have been approved in the US and Europe. One, a treatment for blindness, in which viruses carry a new gene to the retina, costs $425,000 per eye.

A startup called Intellia Therapeutics is testing a treatment that packages CRISPR into RNA and then into a nanoparticle, with which it hopes to cure a painful inherited liver disease. The aim is to make the gene scissors appear in a person’s cells, cut out the problem gene, and then fade away. The company tested the drug on a patient for the first time in 2020.

It’s not a coincidence that Intellia is treating a liver disease. When dripped into the bloodstream through an IV, lipid nanoparticles tend to all end up in the liver—the body’s house-cleaning organ. “If you want to treat a liver disease, great—anything else, you have a problem,” says Weissman.

But Weissman says he’s figured out how to target the nanoparticles so that they wind up inside bone marrow, which constantly manufactures all red blood cells and immune cells. That would be a hugely valuable trick—so valuable that Weissman wouldn’t tell me how he does it. It’s a secret, he says, “until we get the patents filed.”

He intends to use this technique to try to cure sickle-cell disease by sending new instructions into the cells of the body’s blood factory. He’s also working with researchers who are ready to test on monkeys whether immune cells called T cells can be engineered to go on a seek-and-destroy mission after HIV and cure that infection, once and for all.

What all this means is that the fatty particles of messenger RNA may become a way to edit genomes at massive scales, and on the cheap. A drip drug that allows engineering of the blood system could become a public health boon as significant as vaccines. The burden of sickle-cell, an inherited disease that shortens lives by decades (or, in poor regions, kills during childhood), falls most heavily on Black people in equatorial Africa, Brazil, and the US. HIV has also become a lingering scourge: about two-thirds of people living with the virus, or dying from it, are in Africa.

Moderna and BioNTech have been selling their covid-19 vaccine shots for $20 to $40 a dose. What if that were the cost of genetic modification, too? “We could correct sickle-cell with a single shot,” Weissman says. “We think that is groundbreaking new therapy.”

There are fantastic fortunes to be made in mRNA technology. At least five people connected to Moderna and BioNTech are now billionaires, including Bancel. Weissman is not one of them, though he stands to get patent royalties. He says he prefers academia, where people are less likely to tell him what to research—or, just as important, what not to. He’s always looking for the next great scientific challenge: “It’s not that the vaccine is old news, but it was obvious they were going to work.” Messenger RNA, he says, “has an incredible future.”

https://bit.ly/3mzjlIa





вторник, 12 февраля 2019 г.

This AI-driven microscope from Google could help detect cancer in future

Google showcased its prototype Augmented Reality Microscope (ARM) platform with a new modified light microscope that can detect breast cancer metastases as well as prostate cancer.


Google showcased its prototype Augmented Reality Microscope (ARM) platform with a new modified light microscope that can detect breast cancer metastases as well as prostate cancer.


Google showcased its prototype Augmented Reality Microscope (ARM) platform with a new modified light microscope that can detect breast cancer metastases as well as prostate cancer. The microscope, powered by Artificial Intelligence (AI) and machine learning algorithms enables real-time analysis. It displays the results directly into the field 0f view, unlike traditional analog microscopes that are need users to view the sample through the eyepiece. The magnifications can be between 4-40x and the result is displayed by outlining detected tumor regions with a green contour.


The prototype was showcased during a talk delivered at the Annual Meeting of the American Association for Cancer Research (AACR), with an accompanying paper “An Augmented Reality Microscope for Real-time Automated Detection of Cancer” which is currently under review. The move is aimed at accelerating the adoption of deep learning tools for pathologists globally. Google’s ARM platform can be retrofitted into existing light microscopes as well, which requires low-cost components. The microscope offers several visual feedback, thanks to machine learning algorithms. This includes text, arrows, contours, heatmaps, or animations.
“While both cancer models were originally trained on images from a whole slide scanner with a significantly different optical configuration, the models performed remarkably well on the ARM with no additional re-training,” reads a Google blog post. “Of course, light microscopes have proven useful in many industries other than pathology, and we believe the ARM can be adapted for a broad range of applications across healthcare, life sciences research, and material science,” the post added.


пятница, 30 марта 2018 г.

Plasma treatment for almost all areas of industry

What is plasma?
What is plasma?
What is the plasma?

Plasma technology is based on a simple physical principle. Matter changes its state when energy is supplied to it: solids becomes liquid, and liquids becomes gaseous. If even more energy is supplied to a gas, it is ionized and goes into the energy-rich plasma state, the fourth state of matter.
Plasma was first discovered by Irving Langmuir in 1928. It is not rare; actually, quite the opposite is true. More than 99% of the visible matter in the universe is in the plasma state. It can be seen in its natural form on earth as lightning or as polar light in the Arctic and Antarctic, for example. During a solar eclipse, plasma can be observed as a bright circle of light (corona) around the sun.

With increasing energy input, the state of matter changes from solid to liquid to gaseous. If additional energy is then fed into a gas by means of electrical discharge, the gas will turn into plasma.The term plasma designates matter with a high, unstable energy level. When plasma comes into contact with solid materials like plastics and metals, its energy acts on the surfaces and changes important properties, such as the surface energy.In the manufacturing industry, this principle is used for selective modification of material characteristics. Treatment with Openair® plasma energy causes a targeted and exactly adjustable increase in the adhesiveness and wettability of surfaces. This makes it possible to use completely new (even non-polar) materials and environmentally-friendly, solvent-free (VOC-free) paints andadhesives industrially. Today, many chemical surface treatment processes can be replaced with Openair® plasma treatment.
Because it is easy to use and can be integrated inline, plasma treatment has been used for many years in almost all areas of industry, including automobile engineering, transport, electronics manufacturing, packaging technology, consumer goods, life sciences, textiles and new forms of energy.

The measuring variables that particularly characterize plasma are electron temperature and emission of various species excited in the ultraviolet and visible range.

The only way to pretreat even very thermally sensitive plastics under atmospheric pressure without damage is by using high electron temperature and low ion temperature.

The luminous phenomena (optical emissions) of a relaxing* plasma can be detected with the use of optical emission spectroscopy (OES). To do this, characteristic emission bands of the species excited in the plasma in the visible, and especially in the ultraviolet, range of the spectrum are transmitted by an optical fiber to the evaluation electronics and then further processed with special software. The process monitoring components of the Plasmatreat systems operate according to this principle of optical monitoring. This allows for uniform quality over the entire plasma process.

* Relaxing: The transition of plasma into its basic state. In this process, the excitation energy that was previously supplied is released into the environment in the form of light.

Optical emission spectrum of the plasma in the visible and ultraviolet range

Plasma surface treatment
Atmospheric pressure plasma pretreatment is one of the most efficient surface treatment technologies for cleaning, activating, or coating materials like plastic, metal (such as aluminum), or glass.
Plasma cleaning
Openair® plasma surface pretreatment and plasma cleaning provide the optimal prerequisites for subsequent coating of plastic, metal, aluminum or glass.


Dry plasma cleaning with atmospheric plasma makes it possible to immediately continue processing the materials. The application allows a clean and cost-effective overall surface pretreatment process. Because of the high energy level of the plasma, it can selectively break open the structure of chemical or organic substances on the surface of the material. Using ultrafine cleaning, undesirable substances can be completely removed from even sensitive surfaces. This results in the optimal prerequisites for later coating.

Surface cleaning with plasma

Cleaning deep into the pores of a surface with Openair® plasma. No mechanical damage to the surface, no wet chemistry, environmentally-friendly process.

Safe, ultrafine cleaning of mold release agents, additives, softeners (plasticizers), and hydrocarbons

Micro-fine plasma cleaning removes even the smallest dust particles from plastics, which at first adhere firmly to the surface because of the additives. The plasma causes the particles to detach completely from the substrate. The reject rates valuable paintwork or coatings, such as in the automobile or mobile communication industries, are greatly reduced. By using the chemical-physical reaction in the nano range, high-quality, precisely defined surfaces are achieved.
Advantages of plasma cleaning with Openair® plasma:

  • 100% cleaning
  • No dilution effect (compare to aqueous cleaning)
  • No need for additional consumables (compare to CO2-beam cleaning)
  • Cleaning of the complete material structure surface topography, instead of just peaks (compare to sand blasting)
  • No additional space required – inline integration in the manufacturing line
  • Economical and ecologically efficient surface pretreatment


Openair® plasma systems
Pretreatment with Openair® plasma is suitable for all applications where special surface qualities are critical for subsequent processing. Openair® atmospheric pressure plasma technology makes possible efficient, economical inline processes and customized design of overall production.
Effective plasma film pretreatment without changing mechanical properties
Openair® plasma technology is equally suitable for partial and large-area plasma pretreatment of aluminum foil and plastic films. Thanks to the targeted control of treatment parameters such as temperature, nozzle offset, nozzle width and speed, film materials are cleaned, activated or coated efficiently without the use of additives.


In contrast to other methods (such as the corona procedure), the mechanical property of the material is maintained with plasma treatment; the surface is not damaged.


Plasma systems for the coil coating process – efficient ultrafine cleaning without chemicals or wastewater
An example of the high efficiency of Openair® plasma activation is the manufacture of pre-coated sheet metal (coil coating). This material is needed in the industrial production of household appliances and in the automotive industry.


In the coil coating process, strip metal is provided with a surface coating or varnishing to achieve optimum protection against corrosion and to simplify subsequent production processes. For long-term layer and varnish adhesion, the aluminum strip must first be completely cleaned of rolling oils in an ultrafine cleaning process.



Openair® plasma removes all residues reliably and efficiently while activating the material surface for optimal adhesion and a flawless finish. The Openair® plasma treatment can be integrated inline directly upstream of the coating station in the rolling mill.

Moreover, the dry plasma process is particularly environmentally friendly. The large amounts of chemicals that would otherwise be required for ultrafine cleaning are omitted entirely.

Also, the time- and energy-intensive drying processes necessary in wet chemical treatment are no longer required.

Advantages of Openair® plasma systems for coil coating:

  • High efficiency in the cleaning of aluminum coils
  • Surface activation prior to corrosion protection coating and varnishing
  • Saving water, chemicals and wastewater
  • Possibility of one-sided or two-sided pretreatment
  • Variable nozzle configuration depending on the degree of contamination
  • Cost-efficient inline integration


Openair® plasma activation: high-efficiency surface activation, targeted, selective, environmentally friendly and with long-term stability
Wherever components will be coated, painted or glued in subsequent steps, selective surface activation of the starting materials is indispensable. Many materials require surface modifications, such as for printing with water-based inks, for bonding with long-term stability with VOC-free adhesives, or producing material composites.


Openair® plasma activation ensures especially efficient surface modification of plastic, metal, textiles, glass, recycled and composite materials. Surface energy is targeted by the plasma activation and achieved selectively, exactly where it is needed. The result is clearlybetter wetting capability of the surfaces.



Activate surfaces with plasma

Determination of surface tension with test inks shows that, with low surface tension, wetting is impossible. After activation with Openair® plasma, the surface is fully wettable.

Determination of the surface tension with test inks shows:

With low surface tension, wetting is impossible. After surface modification using Openair® plasma activation, the material surface has significantly better wetting capability.

What does surface activation with atmospheric pressure plasma achieve?

Surface activation with Openair® plasma is especially effective when nonpolar materials have to be treated, such as plastics that consist of long-chain polymers. Such nonpolar surfaces are difficult to bond and coat. Because plasma energy selectively modifies the surface tension, these materials can be processed easily and new material combinations can be produced, as in the adhesive bonding process.
Advantages of Openair® plasma activation:

  • High process speed and safety
  • Large process window due to homogeneous plasma jet
  • Cost-effective, environmentally-friendly surface modification
  • Pretreatment without corona effect, no material contact with high voltage
  • Robot-controlled inline integration in the manufacturing line
PlasmaPlus®: selective plasma coating in all different types of application

All different types of materials like plastic, glass, metal, aluminum, PET film, textiles, etc. can be coated with PlasmaPlus®. Plasma polymerization with the PlasmaPlus® process is already being used successfully for surface coating in a large number of different industrial applications.


Principle of surface coating with Openair® plasma
Surface treatment and plasma coating with the laboratory system Plasmatreater AS400.

Examples of successful PlasmaPlus® applications:
  • Improvement of barrier characteristics of plastics for packaging using plasma polymer nanocoating
  • Paintability with long-term stability and resulting high flexibility in manufacturing thanks to nanocoating with PlasmaPlus®
  • PT Release coatings, for injection molding tools, allow a high number of process cycles without the components having to be stressed with release agents that contain silicone.
  • PT Bond coatings assure long-term adhesion in the adhesive joint.
  • Because of their good barrier effect, corrosion protection coatings with PlasmaPlus® offer extremely high corrosion protection with long term resistance to corrosive electrolytes – especially for aluminum alloys.
The extensive potential of atmospheric pressure plasma technology

Openair® Plasma technology makes it possible for industry to respond to continuously increasing demands on raw materials and materials efficiency, energy savings, and to avoid use of pollutants and chemicals. According to demea (source: Deutsche Materialeffizenz Agentur [German Materials Efficiency Agency]), material costs represent the greatest share of costs by far, at approx. 45.4%, even ahead of personnel costs.
New functionalities with nanocoating
Depending on the application, PlasmaPlus® nanocoating deposits a specific functional coating down into the microstructures of the material surface. This results in high efficiency layers that give the materials completely new properties. The creation of selectively functionalized surfaces means completely new performance for the products of tomorrow. These applications extend from electrically-conductive coatings,
New environmentally-friendly processes and end products
Using dry Openair® Plasma technology, many wet chemistry processes can be eliminated. Ultrafine cleaning with plasma already replaces entire washing processes, which makes drying that uses a lot of energy unnecessary. High efficiency plasma activation makes the use of environmentally hazardous and health damaging bonding agents and primers unnecessary. The significant improvement in adhesion enables
Innovation with plasma technology: new applications for all areas of industry
The potential range of applications using Openair® Plasma technology is inexhaustible. In many areas of industry, treatment with atmospheric pressure plasma is already firmly established. In other areas – say, in life sciences and new forms of energy, but also in aviation and aerospace – intensive research is being conducted on new application solutions. Today, there are already groundbreaking successes in protective coating of solar cells, the development of fuel cells, and innovative lightweight construction with carbon fiber materials. Initial tests in the treatment of human skin further demonstrate the extensive potential of plasma technology in future breakthroughs.

Innovative solutions for medical technology and the life sciences with Openair® and Aurora Plasma

Sterilizing microcleaning with Openair® Plasma, facilitating new material combinations for implants, functional coating of instruments, clothing and equipment, pretreatment of microfluidics or balloon catheters with Aurora Plasma – all of these open up new options in medical technology and the life sciences.

Clinically safe, sterile, reproducible – wide spectrum of applications for Plasma in medical technology

Manufacturing processes in medical technology demand the highest possible standards that far exceed the demands in most other industries. Surfaces must be not just clean but absolutely flawless or sterile. Beyond that, pre-treatment processes in medical technology must be very reliable and precisely reproducible.

Plasma pre-treatment to improve adhesion of printing inks has been widely used in medical technology for some time. With Openair® Plasma, Plasmatreat has taken it a big step further.


The Openair® plasma process allows for effective adhesion of hard/soft material combinations, applying finishes to membranes (filter media), and plasma functionalization of plastic surfaces. And all that is guaranteed to be aseptic thanks to plasma sterilization.
Advantages:
  • Simple processes with dry, physical plasma treatment
  • Reliable reproducibility of the pre-treatment parameters
  • 100% process monitoring using PES (plasma emissions spectroscopy)
 
Plasmatreat has more than 20 years’ experience of using low-pressure plasma and atmospheric plasma to pretreat polymer surfaces, including treatment steps such as cleaning, adhesion promotion and deposition of functional coatings or layers. In our laboratories in Silicon Valley, we work with partners in industry to develop groundbreaking solutions.

Plasma chemistry with Openair® Plasma – ideal initiator for new reactions

Chemical compounds are still manufactured today almost exclusively in batch processes according to the appropriate formulations. But when highly customized compositions must be created, such as in pharmacology, this traditional approach is very elaborate and difficult to automate.

A continuous reaction technology is required that is characterized by very precisely measured flow and mixing processes. If, for example, the application of energy is needed for targeted initiation of reactions, only conventional heating or an open flame are available. Since any flame causes spontaneous oxidation, direct contact with the chemicals is not possible.
This is not the case with plasma initiation. The function principle of Openair® plasma is such that it will ionize almost any specific process gas at a high level and is therefore ideally suited as an initiator of reactions in chemistry and biochemistry.

More in-depth research into reaction chemistry is currently underway at Hannover University, Germany, where the synthesis of organic compounds using plasma technology is being investigated.

Plasma medicine – can the direct application of Openair® plasma heal wounds?

The term plasma medicine refers to the direct treatment of human cells with plasma. For almost 15 years, the research group under Prof. Gary Friedman at Drexel University (Philadelphia, PA) has pioneered work on the use of atmospheric plasma systems to treat the skin. He was the first to examine the impact of the most varied direct and indirect applications of plasma to human skin. In the process, he discovered a synergetic relationship between bacteria reduction through the application of plasma (plasma disinfection) and wound healing.

Today this work is being pursued intensively at many research institutions internationally. The "Campus PlasmaMed" research program (Leibniz-Institut for Plasma research and technology e.V. ), Düsseldorf University, Bochum University, and the Max Planck Institute in Munich, all in Germany, deserve special mention in this connection.

Plasmatreat has a wealth of experience in the area of disinfection of technical surfaces in medicine, known as plasma sterilization. Openair® plasma jets are extremely effective in treating surfaces in continuous operation. Because of the potential-free nature of plasma energy, it is in principle suitable for the treatment of human skin as well.

Extensive verifications and further development of jet technology are required to get to the point of using it in human medical applications. The development of systems for controlled medical plasma treatments presents tremendous opportunities for the future.

Plasmatreat is engaged in intensive exchanges with universities and institutes with a view to finding more partners to collaborate with in its exploration of the exciting field of plasma medicine.

Plasma disinfection – new methods to disinfect surfaces using atmospheric plasma

Naturally occurring microorganisms such as fungi and bacteria are critically important for the natural recycling of matter and the survival of ecosystems. Microorganisms are even used in the pharmaceutical and food industries to produce specific active ingredients.

On the other hand, bacteria and fungi can cause illness and a toxic reaction can ensue. Even the smallest contamination in industrial production can cause major problems, up to and including product spoilage or even the destruction of entire systems.



Microbial growth without plasma treatment after exposure



Germs are killed by plasma treatment


Plasmatreat works together with leading institutions to implement Openair® plasma technology as a highly effective method of surface disinfection (plasma disinfection). The Openair® plasma process is especially suited for use in safely disinfecting surfaces when combined with pulsed plasma triggering and special process gases. Because plasma is potential free, the inline process is simple to control and its process parameters are 100% reproducible.

Biocompatible implant coating: biofunctionalization with PlasmaPlus® in medical technology

Plasmatreat is a pioneer in the use of atmospheric plasma coating for implants, both as wear protection and as a biocompatible coating that promotes ease of integration with tissue.


Use of Openair® plasma and PlasmaPlus® to manufacture medical plasma polymer coatings, as wear protection or implant coatings, is an extremely promising area of application. The first plasma-coated implants are already in trials.