3D hybrid composite coating technology with scalable surface application

Contact: Prof. Junjie Niu (niu@wum.edu). Our research team, led by Prof. Junjie Niu at the University of Wisconsin-Milwaukee, develops scalable antimicrobial, anti-biofilm, and functional coating technologies designed to prevent microbial attachment, growth, and biofilm formation. The team has strong expertise in durable surface engineering and has developed a hybrid anti-biofilm coating containing lithocholic acid, zinc pyrithione, and cinnamaldehyde within a cross-linked polymer matrix. The coating can be applied by spray or dip coating to metals, plastics, glass, ceramics, tubing, and complex geometries.

The technology has demonstrated strong antimicrobial performance. Coated stainless-steel surfaces achieved approximately 99.9% reduction of E. coli and 99.8% reduction of E. faecalis. Encapsulated forms achieved >99% bacterial reduction in batch testing and approximately 97–98% reduction during continuous-flow testing using Lake Michigan water. The coating maintained >90.9% bacterial reduction after 3,000 abrasion cycles and >99.9% reduction following high-flow testing at 1.99 m/s. Our team has also developed micro/nanohybrid self-cleaning coatings with water contact angles of approximately 150° and patented 3D hybrid composite coating technology, supporting scalable and durable surface modification.

I bring complementary expertise to Prof. Niu’s team through my previous research on a sustainable protein-conjugated reduced graphene oxide (rGO) nanoframework developed as an antimicrobial coating for biomedical applications. The material was produced through a one-pot biosynthetic process using intracellular proteins from Pleurotus sajor-caju and demonstrated at gram scale under ambient conditions. The protein-conjugated rGO was covalently immobilized onto glass to create a stable antimicrobial surface and demonstrated approximately 94% killing of E. coli at 80 µg/mL after 4 h. Cytotoxicity and hemolysis were also evaluated for potential biomedical applications. The immobilized graphene surface inhibited bacterial attachment and colonization primarily through physical interaction and membrane damage.

The practical need for these technologies is also evident from our laboratory experience. Bacteria-containing samples can be restricted from shared analytical instruments because of concerns about contamination of surfaces, tubing, sample compartments, and internal components. Similar contamination and biofilm challenges occur in medical, diagnostic, and research environments.

By combining our team’s >99% antimicrobial performance, scalable coating methods, mechanical durability, patented surface technology, and sustainable protein-graphene expertise, we aim to develop next-generation antimicrobial surfaces for medical devices and contamination-sensitive equipment.

Next steps include validation on medically relevant substrates, clinically relevant microorganisms and biofilms, coating durability, stability, leaching, cytocompatibility, and biocompatibility. We are seeking industry partners for technology transfer, licensing, co-development, sponsored research, and application-specific validation.