Combinatorial materials research applied to the development of new surface coatings: II. Process capability analysis of the coating formulation workflow

A combinatorial process has been developed for the high throughput production and evaluation of surface coatings. The workflow designed for the production of arrays of liquid coatings involves the robotic transfer of aliquots of solutions of raw materials to an array of glass vials and mixing of the coatings using an unconventional magnetic stirring process. An investigation of the capability of the workflow to accurately and repeatedly prepare coating arrays was conducted as a function of solution viscosity and aliquot size. In addition, mixing capability was evaluated as a function of solution viscosity, total solution volume, and mechanism of stirring. Overall, the results of the study indicated that adequate accuracy and repeatability of the coating preparation process can be achieved as long as raw material solutions are designed such that viscosity is below about 250 cP and aliquot sizes are above about 75 μl. With regard to mixing capability, total solution volume was found to have a profound affect as did the stirring mechanism.