Developing a High-Throughput Platform for the Discovery of Sustainable Antibacterial Materials

Abstract

Healthcare-associated infections (HCAIs) pose a significant global health challenge, exacerbated by the rising threat of antimicrobial resistance (AMR). This study introduces a high-throughput platform designed to identify sustainable antibacterial surfaces, exemplified by a copper-silver-zirconium (CuAgZr) alloy library. Utilizing combinatorial synthesis and advanced characterization techniques, material libraries (MatLibs) are generated and evaluated to rapidly screen diverse alloy compositions. The results demonstrate the ability to reproducibly create alloys with significant antimicrobial properties and high hardness, making them suitable for biomedical applications. The study highlights the critical role of compositional precision in developing materials that balance mechanical strength with antibacterial efficacy. Additionally, this approach ensures significant cost-effectiveness, facilitating the identification of economically viable alloy compositions. This research underscores the potential of high-throughput materials science to expedite the discovery of sustainable solutions for reducing HCAIs and addressing AMR, signaling a leap forward in sustainable healthcare material development.

Keywords: antimicrobial resistance; healthcare-associated infections; high-throughput characterization; material library; mechanical properties; sustainable antimicrobial surfaces.

Figure 1

Combinatorial synthesis and high-throughput characterization of CuAgZr alloy libraries for biomedical applications. (a) Configuration of targets within the PVD chamber, leading to the creation of seven CuAgZr MatLibs with the same chemical gradient utilized in this study. The material library was created in the form of 21 circular patches with a diameter of 5 mm. (b) Results of chemical and microstructure analysis. The ellipses on the ternary system show the actual chemical composition gradient within each of the studied patches. The color corresponds to the thickness of the coating, indicating its differences depending on the position of a given area in relation to the magnetrons during synthesis. XRD analysis allowed for the identification of amorphous areas and crystalline ones with an FCC structure. Microscopic studies (SEM and TEM) and EDX revealed chemical and structural differences between amorphous and crystalline samples, emphasizing the morphology of the surface and the uniform distribution of elements in the amorphous sample (#11). (c) Correlation between the alloys’ chemical composition and their hardness. The contour lines and color gradient represent different levels of hardness, with the area labeled “>5 GPa” indicating regions of particularly high hardness. (d) Antibacterial efficacy assessed through agar plating assay and ion release tests with ICP-OES. The left ternary diagram shows areas where CuAgZr alloys successfully killed S. aureus, while the right diagram shows the copper ion concentration from the selected patches as detected by ICP-OES. The agar plates beneath demonstrate actual antibacterial results from selected patches. (e) Material cost-effectiveness plot identifying the most promising candidates for further development based on a balance between the structure, mechanical properties, antibacterial activity, and alloy cost. (f) Implementation of sustainable antibacterial materials. This graphic illustrates potential applications including coatings for surgical tools and implants, operating room surfaces, and antibacterial additives for textiles. The best alloys can be manufactured in bulk form for entire tools, implants, and furniture in operating rooms, indicating that material selection utilizing this technology is not limited to mere surface treatments. High-throughput combinatorial studies enhance market resilience to geopolitical shifts and related raw material access issues, allowing for the rapid substitution of elements if access becomes restricted.