SBIR-STTR Award

Physical models of proteins have been proven useful in science classrooms at the high school, undergraduate and graduate levels. These models become discovery tools in the hands of students, turning the abstract concepts of molecular structure and function into something real. Unfortunately, the current method of producing these models, by rapid prototyping in a one-at-a-time process, is too costly to allow the widespread dissemination of models in an educational setting. Therefore, the goal of this project is to develop the technology needed to produce physical models of proteins by a novel injection molding process. We will address two problems that currently prevent the production of low cost physical models of proteins by injection molding. First, we will develop the ability to "unfold" the complex geometry of a protein into an unfolded state that is amenable to injection molding. Second, we will further develop PHAST, a proprietary rapid tooling method that creates hardened metal injection molding tools by a process involving mold masters created by rapid prototyping, and a series of casting steps involving ceramic materials and powdered metal. These two innovations will be applied to the creation of a physical model of the MHC protein complex by injection molding.

Thesaurus Terms:
model design /development, protein structure, structural model ceramic, major histocompatibility complex, method development, protein folding

The goal of this project is to develop the technology needed to produce accurate, low-cost physical models of proteins and other molecular structures by an injection molding approach. Two different technical innovations are required to make this possible. First, new software will be created to allow the unfolding of the complex geometry of a protein into a collection of fragments, each of which is moldable. Second, further development of the PHAST rapid tooling process will be required. In this process, ceramic molds are first cast from a complex master-pattern created by rapid prototyping. The final metal injection molding tool is then created from powdered metal packed against the ceramic mold and infiltrated at high temperature with a molten copper alloy. This approach creates a hard metal injection mold with a complex geometry that would be virtually impossible to create by traditional methods, at a fraction of the cost of traditional machining. The successful completion of this project will result in the production of a collection of physical models that can be used to introduce students to concepts of molecular structure and function. No other technology currently exists with which physical models of these structures can be produced at a cost that will allow their widespread dissemination. The physical models of proteins and other molecular structures that will result from this project will be used in science classrooms at both the secondary and undergraduate levels to attract a broader spectrum of students to careers in the molecular biosciences. These physical models are especially useful in capturing the interest of under-represented minority students who might not otherwise develop an interest in pursuing careers in science