Accelerating 3D printing for surface wettability research

The wettability of a surface is affected by its physical and chemical properties, but it can be modulated by patterning it. Researchers use many different techniques for surface patterning, each one with different trade-offs in terms of cost, flexibility, convenience and realizable geometries. Very high-resolution 3D printing technologies (such as stereolithography by two-photon absorption) have the potential to greatly increase the range of realizable surface geometries, but they are currently not in wide use because they are too slow for printing the relative large surface areas required for wetting experiments. To enable the use of these 3D techniques, we are developing new slicing algorithms able to speed up 3D-printing technologies.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Three-dimensional microfabrication through a multimode optical fiber

Additive manufacturing, also known as 3D printing, is an advanced manufacturing technique that allows the fabrication of arbitrary macroscopic and microscopic objects. All 3D printing systems require large optical elements or nozzles in proximity to the built structure. This prevents their use in applications in which there is no direct access to the area where the objects have to be printed. Here, we demonstrate three-dimensional microfabrication based on two-photon polymerization (TPP) with sub diffraction-limited resolution through an ultra-thin, 50 mm long printing nozzle of 560 micrometers in diameter. Using wavefront shaping, femtosecond infrared pulses are focused and scanned through a multimode optical fiber (MMF) inside a photoresist that polymerizes via two-photon absorption. We show the construction of arbitrary 3D structures of 500 nm resolution on the other side of the fiber. To our knowledge, this is the first demonstration of microfabrication through a multimode optical fiber. Our work represents a new area which we refer to as endofabrication

Multiresolution Layered Manufacturing

PURPOSE: Two-photon polymerization (TPP) has become one of the most popular techniques for stereolithography at very high resolutions. When printing relatively large structures at high resolutions, one of the main limiting factors is the printing time. The goal of this work is to present a new slicing algorithm to minimize printing times. DESIGN/METHODOLOGY/APPROACH: Typically, slicing algorithms used for TPP do not take into account the fact that TPP can print at a range of resolutions (i.e. with different heights and diameters) by varying parameters such as exposure time, laser power, photoresist properties, and optical arrangements. This work presents Multiresolution Layered Manufacturing (MLM), a novel slicing algorithm that processes 3D structures to separate parts manufacturable at low resolution from those that require a higher resolution. FINDINGS: MLM can significantly reduce the printing time of 3D structures at high resolutions. The maximum theoretical speed-up depends on the range of printing resolutions, but the effective speed-up also depends on the geometry of each 3D structure. RESEARCH LIMITATIONS/IMPLICATIONS: MLM opens the possibility to significantly decrease printing times, potentially opening the use of TPP to new applications in many disciplines such as microfluidics, metamaterial research or wettability. ORIGINALITY/VALUE: There are many instances of previous research on printing at several resolutions. However, in most cases, the toolpaths have to be manually arranged. In some cases, previous research also automates the generation of toolpaths, but they are limited in various ways. MLM is the first algorithm to comprehensively solve this problem for a wide range of true 3D structures.NANO3D (a BEWARE Fellowship from the Walloon Region, Belgium, part of the Marie Curie Programme of the ERC). IAP 7/38 MicroMAST (Interuniversity Attraction Poles Programme from the Belgian Science Policy Office, the Walloon Region and the FNRS)

Thiol-gelatin-norbornene bioink for laser‐based high‐definition bioprinting

Two-photon polymerization (2PP) is a lithography-based 3D printing method allowing the fabrication of 3D structures with sub-micrometer resolution. This work focuses on the characterization of gelatin-norbornene (Gel-NB) bioinks which enables the embedding of cells via 2PP. The high reactivity of the thiol-ene system allows 2PP processing of cell-containing materials at remarkably high scanning speeds (1000 mm s(-1)) placing this technology in the domain of bioprinting. Atomic force microscopy results demonstrate that the indentation moduli of the produced hydrogel constructs can be adjusted in the 0.2-0.7 kPa range by controlling the 2PP processing parameters. Using this approach gradient 3D constructs are produced and the morphology of the embedded cells is observed in the course of 3 weeks. Furthermore, it is possible to tune the enzymatic degradation of the crosslinked bioink by varying the applied laser power. The 3D printed Gel-NB hydrogel constructs show exceptional biocompatibility, supported cell adhesion, and migration. Furthermore, cells maintain their proliferation capacity demonstrated by Ki-67 immunostaining. Moreover, the results demonstrate that direct embedding of cells provides uniform distribution and high cell loading independently of the pore size of the scaffold. The investigated photosensitive bioink enables high-definition bioprinting of well-defined constructs for long-term cell culture studies

High-Kinetic Inductance Additive Manufactured Superconducting Microwave Cavity

Investigations into the microwave surface impedance of superconducting resonators have led to the development of single photon counters that rely on kinetic inductance for their operation. While concurrent progress in additive manufacturing, `3D printing', opens up a previously inaccessible design space for waveguide resonators. In this manuscript, we present results from the first synthesis of these two technologies in a titanium, aluminum, vanadium (Ti-6Al-4V) superconducting radio frequency resonator which exploits a design unattainable through conventional fabrication means. We find that Ti-6Al-4V has two distinct superconducting transition temperatures observable in heat capacity measurements. The higher transition temperature is in agreement with DC resistance measurements. While the lower transition temperature, not previously known in literature, is consistent with the observed temperature dependence of the superconducting microwave surface impedance. From the surface reactance, we extract a London penetration depth of $8\pm3{\mu}$m - roughly an order of magnitude larger than other titanium alloys and several orders of magnitude larger than other conventional elemental superconductors. This large London penetration depth suggests that Ti-6Al-4V may be a suitable material for high kinetic inductance applications such as single photon counting or parametric amplification used in quantum computing.Comment: 4 pages, 4 figure

Structural Color 3D Printing By Shrinking Photonic Crystals

The rings, spots and stripes found on some butterflies, Pachyrhynchus weevils, and many chameleons are notable examples of natural organisms employing photonic crystals to produce colorful patterns. Despite advances in nanotechnology, we still lack the ability to print arbitrary colors and shapes in all three dimensions at this microscopic length scale. Commercial nanoscale 3D printers based on two-photon polymerization are incapable of patterning photonic crystal structures with the requisite ~300 nm lattice constant to achieve photonic stopbands/ bandgaps in the visible spectrum and generate colors. Here, we introduce a means to produce 3D-printed photonic crystals with a 5x reduction in lattice constants (periodicity as small as 280 nm), achieving sub-100-nm features with a full range of colors. The reliability of this process enables us to engineer the bandstructures of woodpile photonic crystals that match experiments, showing that observed colors can be attributed to either slow light modes or stopbands. With these lattice structures as 3D color volumetric elements (voxels), we printed 3D microscopic scale objects, including the first multi-color microscopic model of the Eiffel Tower measuring only 39-microns tall with a color pixel size of 1.45 microns. The technology to print 3D structures in color at the microscopic scale promises the direct patterning and integration of spectrally selective devices, such as photonic crystal-based color filters, onto free-form optical elements and curved surfaces

3D printing of optical materials: an investigation of the microscopic properties

3D printing technologies are currently enabling the fabrication of objects with complex architectures and tailored properties. In such framework, the production of 3D optical structures, which are typically based on optical transparent matrices, optionally doped with active molecular compounds and nanoparticles, is still limited by the poor uniformity of the printed structures. Both bulk inhomogeneities and surface roughness of the printed structures can negatively affect the propagation of light in 3D printed optical components. Here we investigate photopolymerization-based printing processes by laser confocal microscopy. The experimental method we developed allows the printing process to be investigated in-situ, with microscale spatial resolution, and in real-time. The modelling of the photo-polymerization kinetics allows the different polymerization regimes to be investigated and the influence of process variables to be rationalized. In addition, the origin of the factors limiting light propagation in printed materials are rationalized, with the aim of envisaging effective experimental strategies to improve optical properties of printed materials.Comment: 8 pages, 3 figure