Novel materials are the backbone of major technological advances. However, the development and wide-scale introduction of new materials, such as nanomaterials, is limited by three main factors—the expense of experiments, inefficiency of synthesis methods and complexity of scale-up. Reaching the kilogram scale is a hurdle that takes years of effort for many nanomaterials. We introduce an improved methodology for materials development, combining state-of-the-art techniques—multi-objective machine learning optimization, high yield microreactors and high throughput analysis. We demonstrate this approach through the optimization of ZnO nanoparticle synthesis, simultaneously targeting high yield and high antibacterial activity. In fewer than 100 experiments, we developed a 1 kg day⁻¹ continuous synthesis for ZnO (with a space-time-yield of 62.4 kg day⁻¹ m⁻³), having an antibacterial activity comparable to hydrothermally synthesized nano-ZnO and cetrimonium bromide. Following this, we provide insights into the mechanistic factors underlying the performance-yield tradeoffs of synthesis and highlight the need for benchmarking machine learning models with traditional chemical engineering methods. Methods for increasing model accuracy at steep pareto fronts, in this case at yields close to 1 kg per day, should also be improved. To project the next steps for process scale-up and the potential advantages of this methodology, we conduct a scalability analysis in comparison to conventional batch production methods, in which there is a significant reduction in degrees of freedom. The proposed method has the potential to significantly reduce experimental costs, increase process efficiency and enhance material performance, which culminate to form a new pathway for materials discovery.

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New material innovation is limited by the time, expertise and cost of development. In the face of rapidly growing crises like pandemics, resource scarcity and climate change, we require new methods and methodologies to create and scale-up new technologies. In this work, we introduce an accelerated platform for material development, featuringadvanced machine learning methods, continuous microreactors and automation. As a case study, this platform was used to develop highly antimicrobial zinc oxide materials for coatings, with simultaneously optimized yield and performance. Continuous, high-shear microreactors and tangential flow filtration were employed at the lab-scale to enhance space time yields and scalability via number-up and scale-out, and culminating in ~ kg/day scale production.Decision-making was accelerated with the use of a multi-objective optimization algorithm for experimental design,allowing fast exploration of many variables without lengthy factorial designs and heuristic scale-up techniques.Furthermore, this platform was used to probe relationships between material characteristics (such as morphology and crystallinity), application performance and process parameters, showcasing the capability of this platform to make new discoveries and mechanistic insights. This approach features broad applicability to a range of materials and industries,including energy storage, pharmaceuticals and catalysis.@en

Many engineering problems require the optimization of expensive, black-box functions involving multiple conflicting criteria, such that commonly used methods like multiobjective genetic algorithms are inadequate. To tackle this problem several algorithms have been developed using surrogates. However, these often have disadvantages such as the requirement of a priori knowledge of the output functions or exponentially scaling computational cost with respect to the number of objectives. In this paper a new algorithm is proposed, TSEMO, which uses Gaussian processes as surrogates. The Gaussian processes are sampled using spectral sampling techniques to make use of Thompson sampling in conjunction with the hypervolume quality indicator and NSGA-II to choose a new evaluation point at each iteration. The reference point required for the hypervolume calculation is estimated within TSEMO. Further, a simple extension was proposed to carry out batch-sequential design. TSEMO was compared to ParEGO, an expected hypervolume implementation, and NSGA-II on nine test problems with a budget of 150 function evaluations. Overall, TSEMO shows promising performance, while giving a simple algorithm without the requirement of a priori knowledge, reduced hypervolume calculations to approach linear scaling with respect to the number of objectives, the capacity to handle noise and lastly the ability for batch-sequential usage.

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Dynamic modeling is an important tool to gain better understanding of complex bioprocesses and to determine optimal operating conditions for process control. Currently, two modeling methodologies have been applied to biosystems: kinetic modeling, which necessitates deep mechanistic knowledge, and artificial neural networks (ANN), which in most cases cannot incorporate process uncertainty. The goal of this study is to introduce an alternative modeling strategy, namely Gaussian processes (GP), which incorporates uncertainty but does not require complicated kinetic information. To test the performance of this strategy, GPs were applied to model microalgae growth and lutein production based on existing experimental datasets and compared against the results of previous ANNs. Furthermore, a dynamic optimization under uncertainty is performed, avoiding over-optimistic optimization outside of the model's validity. The results show that GPs possess comparable prediction capabilities to ANNs for long-term dynamic bioprocess modeling, while accounting for model uncertainty. This strongly suggests their potential applications in bioprocess systems engineering.

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Automated development of chemical processes requires access to sophisticated algorithms for multi-objective optimization, since single-objective optimization fails to identify the trade-offs between conflicting performance criteria. Herein we report the implementation of a new multi-objective machine learning optimization algorithm for self-optimization, and demonstrate it in two exemplar chemical reactions performed in continuous flow. The algorithm successfully identified a set of optimal conditions corresponding to the trade-off curve (Pareto front) between environmental and economic objectives in both cases. Thus, it reveals the complete underlying trade-off and is not limited to one compromise as is the case in many other studies. The machine learning algorithm proved to be extremely data efficient, identifying the optimal conditions for the objectives in a lower number of experiments compared to single-objective optimizations. The complete underlying trade-off between multiple objectives is identified without arbitrary weighting factors, but via true multi-objective optimization.

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