Structural color three-dimensional printing by shrinking photonic crystals

Hydrogen Bond-Mediated Self-Shielded Moisture-Responsive Structural Color for Time-Temperature Indicating

Effective monitoring of the time-temperature history of biological reagents, chemical drugs, and perishable foods during cold chain storage is crucial for ensuring their quality and efficacy. Time-temperature indicators (TTIs) are developed to assess the cumulative impact of time and temperature on product quality. However, current indicators face challenges related to complex wrapping procedures, narrow tracking ranges, susceptibility to photobleaching, and pre-use instability, hampering widespread use. Herein, the first moisture-responsive 1D photonic crystal (1DPC) TTIs featuring robust structural colors, customizable time-temperature ranges, and reliable renewability are demonstrated. The indicators exhibit distinct color-changing responsiveness toward water vapor, which remains observable after prolonged storage at low temperatures. Significantly, the moisture responsiveness gradually diminishes at elevated temperatures over time due to ambient water-induced hydrogen bond formation, effectively shielding the indicator from external stimuli. This property enables the naked-eye inspection of product efficacy during cold chain storage. Additionally, the endowed flexibility of the TTI facilitates its easy attachment to targets, functioning as a convenient indicator label. Remarkably, the indicator can be stably stored for an extended period at room temperature before use, thereby showcasing substantial market potential.

Direct laser writing-enabled 3D printing strategies for microfluidic applications

Over the past decade, additive manufacturing-or "three-dimensional (3D) printing"-has attracted increasing attention in the Lab on a Chip community as a pathway to achieve sophisticated system architectures that are difficult or infeasible to fabricate via conventional means. One particularly promising 3D manufacturing technology is "direct laser writing (DLW)", which leverages two-photon (or multi-photon) polymerization (2PP) phenomena to enable high geometric versatility, print speeds, and precision at length scales down to the 100 nm range. Although researchers have demonstrated the potential of using DLW for microfluidic applications ranging from organ on a chip and drug delivery to micro/nanoparticle processing and soft microrobotics, such scenarios present unique challenges for DLW. Specifically, microfluidic systems typically require macro-to-micro fluidic interfaces (e.g., inlet and outlet ports) to facilitate fluidic loading, control, and retrieval operations; however, DLW-based 3D printing relies on a micron-to-submicron-sized 2PP volume element (i.e., "voxel") that is poorly suited for manufacturing these larger-scale fluidic interfaces. In this Tutorial Review, we highlight and discuss the four most prominent strategies that researchers have developed to circumvent this trade-off and realize macro-to-micro interfaces for DLW-enabled microfluidic components and systems. In addition, we consider the possibility that-with the advent of next-generation commercial DLW printers equipped with new dynamic voxel tuning, print field, and laser power capabilities-the overall utility of DLW strategies for Lab on a Chip fields may soon expand dramatically.

Multiphoton lithography with protein photoresists

Recently, 2D/3D direct laser writing has attracted increased attention due to its broad applications ranging from biomedical engineering to aerospace. 3D nanolithography of water-soluble protein-based scaffolds have been envisioned to provide a variety of tunable properties. In this paper, we present a functional protein-based photoresist with tunable mechanical properties that is suitable for multiphoton lithography (MPL). Through the use of methacrylated streptavidin or methacrylated bovine serum albumin in combination with polyethylene glycol diacrylate or methacrylated hyaluronic acid as crosslinkers and a vitamin-based photoinitiator, we were able to write two- and three-dimensional structures as small as 200 nm/600 nm lateral/axial features, respectively. We also demonstrated that Young's modulus can be tuned by the photoresist composition, and we were able to achieve values as low as 40 kPa. Furthermore, we showed that Young's modulus can be recovered after drying and rehydration (i.e. shelf time determination). The retained biological functionality of the streptavidin scaffolds was demonstrated using fluorescently labelled biotins. Using single-molecule fluorescence microscopy, we estimated the density of streptavidin in the written features (1.8 ± 0.2 × 105 streptavidins per 1.00 ± 0.05 μm³ of feature volume). Finally, we showed applicability of our 2D scaffold as a support for a fluorescence absorbance immuno-assay (FLISA), and as a delivery platform of extracellular vesicles to HeLa cells.

Light and matter co-confined multi-photon lithography

Mask-free multi-photon lithography enables the fabrication of arbitrary nanostructures low cost and more accessible than conventional lithography. A major challenge for multi-photon lithography is to achieve ultra-high precision and desirable lateral resolution due to the inevitable optical diffraction barrier and proximity effect. Here, we show a strategy, light and matter co-confined multi-photon lithography, to overcome the issues via combining photo-inhibition and chemical quenchers. We deeply explore the quenching mechanism and photoinhibition mechanism for light and matter co-confined multiphoton lithography. Besides, mathematical modeling helps us better understand that the synergy of quencher and photo-inhibition can gain a narrowest distribution of free radicals. By using light and matter co-confined multiphoton lithography, we gain a 30 nm critical dimension and 100 nm lateral resolution, which further decrease the gap with conventional lithography.

Diffractive optical computing in free space

Structured optical materials create new computing paradigms using photons, with transformative impact on various fields, including machine learning, computer vision, imaging, telecommunications, and sensing. This Perspective sheds light on the potential of free-space optical systems based on engineered surfaces for advancing optical computing. Manipulating light in unprecedented ways, emerging structured surfaces enable all-optical implementation of various mathematical functions and machine learning tasks. Diffractive networks, in particular, bring deep-learning principles into the design and operation of free-space optical systems to create new functionalities. Metasurfaces consisting of deeply subwavelength units are achieving exotic optical responses that provide independent control over different properties of light and can bring major advances in computational throughput and data-transfer bandwidth of free-space optical processors. Unlike integrated photonics-based optoelectronic systems that demand preprocessed inputs, free-space optical processors have direct access to all the optical degrees of freedom that carry information about an input scene/object without needing digital recovery or preprocessing of information. To realize the full potential of free-space optical computing architectures, diffractive surfaces and metasurfaces need to advance symbiotically and co-evolve in their designs, 3D fabrication/integration, cascadability, and computing accuracy to serve the needs of next-generation machine vision, computational imaging, mathematical computing, and telecommunication technologies.

Tuning disorder in structurally colored bioinspired photonic glasses

Colloidal crystals, such as opals, display bright and iridescent colors when assembled from submicron particles. While the brightness and purity of iridescent colors are well suited for ornaments, signaling, and anticounterfeiting, their angle dependence limits the range of their applications. In contrast, colloidal glasses display angle-independent structural color that is tunable by the size and local arrangement of particles. However, the angle-independent color of colloidal photonic glasses usually yields pastel colors that are not vivid due to the disorder in the particle assembly. Here, we report an electrophoretic assembly platform for tuning the level of disorder in the particle system from a colloidal crystal to a colloidal glass. Altering the electric field in our electrophoretic platform allows for deliberate control of the assembly kinetics and thus the level of order in the particle assembly. With the help of microscopy, X-ray scattering, and optical characterization, we show that the photonic properties of the assembled films can be tuned with the applied electric field. Our analyses reveal that angle-independent color with optimum color brightness can be achieved in typical colloidal suspensions when the range of order is at ∼3.2 particle diameters, which is expected at a moderate electric field of ∼15 V mm-1.

3D-Printed Biomimetic Structural Colors

Resolution control and expansibility have always been challenges to the fabrication of structural color materials. Here, a facile strategy to print cholesteric liquid crystal elastomers (CLCEs) into complex structural color patterns with variable resolution and enhanced expansibility is reported. A volatile solvent is introduced into the synthesized CLC oligomers, modifying its rheological properties and allowing direct-ink-writing (DIW) under mild conditions. The combination of printing shear flow and anisotropic deswelling of ink drives the CLC molecules into an ordered cholesteric arrangement. The authors meticulously investigate the influence of printing parameters to achieve resolution control over a wide range, allowing for the printing of multi-sized 1D or 2D patterns with constant quality. Furthermore, such solvent-cast direct-ink-writing (DIW) strategy is highly expandable and can be integrated easily into the DIW of bionic robots. Multi-responsive bionic butterfly and flower are printed with biomimetic in both locomotion and coloration. Such designs dramatically reduced the processing difficulty of precise full-color printing and expanded the capability of structural color materials to collaborate with other systems.

Reconfigurable Photonic Crystal Reversibly Exhibiting Single and Double Structural Colors

Unlike absorption-based colors of dyes and pigments, reflection-based colors of photonic crystals, so called "structural colors", are responsive to external stimuli, but can remain unfaded for over ten million years, and therefore regarded as a next-generation coloring mechanism. However, it is a challenge to rationally design the spectra of structural colors, where one structure gives only one reflection peak defined by Bragg's law, unlike those of absorption-based colors. Here, we report a reconfigurable photonic crystal that exhibits single-peak and double-peak structural colors. This photonic crystal is composed of a colloidal nanosheet in water, which spontaneously adopts a layered structure with single periodicity (407 nm). After a temperature-gradient treatment, the photonic crystal segregates into two regions with shrunken (385 nm) and expanded (448 nm) periodicities, and thus exhibits double reflection peaks that are blue- and red-shifted from the original one, respectively. Notably, the transition between the single-peak and double-peak states is reversible.

Quasi-Random Multimetallic Nanoparticle Arrays

This paper describes a nanofabrication procedure that can generate multiscale substrates with quasi-random microregions of nanoparticle arrays having different periodicities and metals. We combine cycles of large-area nanoparticle array fabrication with solvent-assisted wrinkle lithography to mask and etch quasi-random areas of prefabricated nanoparticles to control the fill factors of the arrays. The approach is highly flexible, and parameters, including nanoparticle size and material, array geometry, and fill factor, can be tailored independently. Multimetallic nanoparticle arrays can support surface lattice resonances at fill factors as low as 20% and can function as nanoscale cavities for lasing action with as few as 10% of the nanoparticles in an array. We demonstrated that multimetallic nanoparticle substrates that combine two or three arrays with different periodicities can exhibit lasing responses over visible and near-infrared wavelengths. Our work showcases the robust optical responses of multimetallic and periodic devices for broadband light manipulation.

Light-Based 3D Printing of Complex-Shaped Photonic Colloidal Glasses

Colloidal glasses display angle-independent structural color that is tunable by the size and local arrangement of sub-micrometer particles. While films, droplets, and microcapsules with isotropic structural color have been demonstrated, the shaping of colloidal glasses in three dimensions remains an open manufacturing challenge. Here, a light-based printing platform for the shaping of colloidal glasses into 3D objects featuring complex geometries and vivid structural color after thermal treatment is reported. Rheology, photopolymerization, and calcination experiments are performed to design the photoreactive resins leading to printable colloidal glasses. With the help of microscopy, scattering, and optical characterization, it is shown that the photonic properties of the printed objects reflect the locally ordered microstructure of the glass. The capability of the platform in creating 3D objects with isotropic structural color is illustrated by printing lattices and miniaturized sculpture replicas with unique shapes and multimaterial designs.

3D Imprinting of Voxel-Level Structural Colors in Lithium Niobate Crystal

Advanced coloration methods are of pivotal importance in science, technology, and engineering. However, 3D structural colors that are critical for emerging multidimensional information representation and recording are rarely achievable. Here, a facile voxel-level programmable 3D structural coloration in the bulk lithium niobate (LiNbO3 ) crystal is reported. This is achieved by engineering wavelength-selective interference between ordinary (O) and extraordinary (E) light in the crystal matrix. To induce effective phase contrast between O and E light for establishing the highly localized interference across the visible band, the presence of a pulse-internal-coupling effect is revealed in the single-pulse ultrafast laser-crystal interaction and an ultrafast-laser-induced micro-amorphization (MA) strategy is thus developed to manipulate local matrix structure. Consequently, micro-nanoscale colorful voxels can be fast inscribed into any spatial position of the crystal matrix in one step. It is demonstrated that the colors can be flexibly manipulated and quickly extracted in 3D space. Multidimensional MA-color data storage with large capacity, high writing and readout speed, long lifetime, and excellent stability under harsh conditions is achieved. The present principle enables multifunctional 3D structural coloration devices inside high-refractive-index transparent dielectrics and can serve as a general platform to innovate next-generation information optics.

Dynamic Color-Switching of Hydrogel Micropillar Array under Ethanol Vapor for Optical Encryption

Responsive structural colors from artificially engineered micro/nanostructures are critical to the development of anti-counterfeiting, optical encryption, and intelligent display. Herein, the responsive structural color of hydrogel micropillar array is demonstrated under the external stimulus of ethanol vapor. Micropillar arrays with full color are fabricated via femtosecond laser direct writing by controlling the height and diameter of the micropillars according to the FDTD simulation. Color-switching of the micropillar arrays is achieved in <1 s due to the formation of liquid film among micropillars. More importantly, the structural color blueshift of the micropillar arrays is sensitive to the micropillar diameter, instead of the micropillar height. The micropillar array with a diameter of 772 nm takes 400 ms to complete blueshift under ethanol vapor, while that with a diameter of 522 nm blueshifts at 2400 ms. Microscale patterns are realized by employing the size-dependent color-switching of designed micropillar arrays under ethanol vapor. Moreover, Morse code and directional blueshift of structural colors are realized in the micropillar arrays. The advantages of controllable color-switching of the hydrogel micropillar array would be prospective in the areas of optical encryption, dynamic display, and anti-counterfeiting.

Form birefringent polymeric structures realized by 3D laser printing

The 3D laser printing of form birefringent structures promises fast prototyping of polarization-sensitive photonic elements. However, achieving the quarter- and half-wave phase retardation levels needed in applications still remains a challenge, especially at visible wavelengths. Thickness of the birefringent region, usually consisting of simple 1D gratings, must be sufficiently large to ensure the required retardance, making the 3D laser-printed gratings prone to mechanical collapse. Here we demonstrate 3D laser-printed mechanically robust form birefringent 3D structures whose thickness and phase retardation can be increased without loss of mechanical stability, and report on the realization of compact self-supporting structures exhibiting quarter- and half-wave phase retardation at visible wavelengths.

Computational design of anisotropic stealthy hyperuniform composites with engineered directional scattering properties

Disordered hyperuniform materials are an emerging class of exotic amorphous states of matter that endow them with singular physical properties, including large isotropic photonic band gaps, superior resistance to fracture, and nearly optimal electrical and thermal transport properties, to name but a few. Here we generalize the Fourier-space-based numerical construction procedure for designing and generating digital realizations of isotropic disordered hyperuniform two-phase heterogeneous materials (i.e., composites) developed by Chen and Torquato [Acta Mater. 142, 152 (2018)1359-645410.1016/j.actamat.2017.09.053] to anisotropic microstructures with targeted spectral densities. Our generalized construction procedure explicitly incorporates the vector-dependent spectral density function χ[over ̃]_{_{V}}(k) of arbitrary form that is realizable. We demonstrate the utility of the procedure by generating a wide spectrum of anisotropic stealthy hyperuniform microstructures with χ[over ̃]_{_{V}}(k)=0 for k∈Ω, i.e., complete suppression of scattering in an "exclusion" region Ω around the origin in Fourier space. We show how different exclusion-region shapes with various discrete symmetries, including circular-disk, elliptical-disk, square, rectangular, butterfly-shaped, and lemniscate-shaped regions of varying size, affect the resulting statistically anisotropic microstructures as a function of the phase volume fraction. The latter two cases of Ω lead to directionally hyperuniform composites, which are stealthy hyperuniform only along certain directions and are nonhyperuniform along others. We find that while the circular-disk exclusion regions give rise to isotropic hyperuniform composite microstructures, the directional hyperuniform behaviors imposed by the shape asymmetry (or anisotropy) of certain exclusion regions give rise to distinct anisotropic structures and degree of uniformity in the distribution of the phases on intermediate and large length scales along different directions. Moreover, while the anisotropic exclusion regions impose strong constraints on the global symmetry of the resulting media, they can still possess structures at a local level that are nearly isotropic. Both the isotropic and anisotropic hyperuniform microstructures associated with the elliptical-disk, square, and rectangular Ω possess phase-inversion symmetry over certain range of volume fractions and a percolation threshold ϕ_{c}≈0.5. On the other hand, the directionally hyperuniform microstructures associated with the butterfly-shaped and lemniscate-shaped Ω do not possess phase-inversion symmetry and percolate along certain directions at much lower volume fractions. We also apply our general procedure to construct stealthy nonhyperuniform systems. Our construction algorithm enables one to control the statistical anisotropy of composite microstructures via the shape, size, and symmetries of Ω, which is crucial to engineering directional optical, transport, and mechanical properties of two-phase composite media.

Highly hydrostable and flexible opal photonic crystal film for enhanced up-conversion fluorescence sensor of COVID-19 antibody

Efficient detection of related markers is significant for the early screening of COVID-19. Near infrared (NIR) light excited up-conversion fluorescence probes are ideal for biosensing but limited by the low luminescence efficiency. In this work, a novel highly stable opal photonic crystal (OPC) structure was designed to provide an OPC effect for up-conversion fluorescence enhancement, and sensitive Novel Coronavirus IgG up-conversion FRET-based sensor was further constructed. For the problems of water stability and mechanical stability of polymer OPC which cannot be solved for a long time, polymer spray combined with a flipped OPC film strategy is presented. Fragmented size OPC film was firmly fixed by polymer modification layer, which gave large size OPC film great water stability, mechanical stability and bending performance without affecting the fluorescence enhancement property. On this basis, the up-conversion emission intensity was enhanced significantly, and fluorescence resonant energy transfer (FRET) based Novel Coronavirus IgG antibody sensor was constructed. Monolayer up-conversion nanoparticles (UCNPs) on the surface of the polydopamine (PDA)/OPC film can make the fluorescent signal more sensitive, and effectively reduce the detection limit. The test device integrating NIR excitation and mobile phone realized the visual fast detection, showing remarkable sensing performance for COVID-19 antibodies with the limit of detection (LOD) of 0.1 ng mL-1. This detection platform will provide a more effective tool for early detection of the novel coronavirus.

Pick and place process for uniform shrinking of 3D printed micro- and nano-architected materials

Two-photon polymerization lithography is promising for producing three-dimensional structures with user-defined micro- and nanoscale features. Additionally, shrinkage by thermolysis can readily shorten the lattice constant of three-dimensional photonic crystals and enhance their resolution and mechanical properties; however, this technique suffers from non-uniform shrinkage owing to substrate pinning during heating. Here, we develop a simple method using poly(vinyl alcohol)-assisted uniform shrinking of three-dimensional printed structures. Microscopic three-dimensional printed objects are picked and placed onto a receiving substrate, followed by heating to induce shrinkage. We show the successful uniform heat-shrinking of three-dimensional prints with various shapes and sizes, without sacrificial support structures, and observe that the surface properties of the receiving substrate are important factors for uniform shrinking. Moreover, we print a three-dimensional mascot model that is then uniformly shrunk, producing vivid colors from colorless woodpile photonic crystals. The proposed method has significant potential for application in mechanics, optics, and photonics.

Realization and Control of Bulk and Surface Modes in 3D Nanomagnonic Networks by Additive Manufacturing of Ferromagnets

The high-density integration in information technology fuels the research on functional 3D nanodevices. Particularly ferromagnets promise multifunctional 3D devices for nonvolatile data storage, high-speed data processing, and non-charge-based logic operations via spintronics and magnonics concepts. However, 3D nanofabrication of ferromagnets is extremely challenging. In this work, an additive manufacturing methodology is reported, and unprecedented 3D ferromagnetic nanonetworks with a woodpile-structure unit cell are fabricated. The collective spin dynamics (magnons) at frequencies up to 25 GHz are investigated by Brillouin Light Scattering (BLS) microscopy and micromagnetic simulations. A clear discrepancy of about 10 GHz is found between the bulk and surface modes, which are engineered by different unit cell sizes in the Ni-based nanonetworks. The angle- and spatially-dependent modes demonstrate opportunities for multi-frequency signal processing in 3D circuits via magnons. The developed synthesis route will allow one to create 3D magnonic crystals with chiral unit cells, which are a prerequisite toward surface modes with topologically protected properties.

Carbon Additive Manufacturing with a Near-Replica "Green-to-Brown" Transformation

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) "green-to-brown" transformation, making a near-geometric replica of the 3D design to produce a "brown" part with full nanomaterials to allow further matrix infill. This demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

Three-Dimensional Printing of Structural Color Using a Femtoliter Meniscus

Structural colors are produced by the diffraction of light from microstructures. The collective arrangement of substructures is a simple and cost-effective approach for structural coloration represented by colloidal self-assembly. Nanofabrication methods enable precise and flexible coloration by processing individual nanostructures, but these methods are expensive or complex. Direct integration of desired structural coloration remains difficult because of the limited resolution, material-specificity, or complexity. Here, we demonstrate three-dimensional printing of structural colors by direct writing of nanowire gratings using a femtoliter meniscus of polymer ink. This method combines a simple process, desired coloration, and direct integration at a low cost. Precise and flexible coloration is demonstrated by printing the desired structural colors and shapes. In addition, alignment-resolved selective reflection is shown for displayed image control and color synthesis. The direct integration facilitates structural coloration on various substrates, including quartz, silicon, platinum, gold, and flexible polymer films. We expect that our contribution can expand the utility of diffraction gratings across various disciplines such as surface-integrated strain sensors, transparent reflective displays, fiber-integrated spectrometers, anticounterfeiting, biological assays, and environmental sensors.

Direct laser writing structural color for reversible encryption and decryption in different mediums

Structural color (SC) has enormous potential for improving the visualization and identification of functional micro/nano structures for information encryption and intelligent sensing. Nevertheless, achieving the direct writing of SCs at the micro/nano scale and the change of color in response to external stimuli simultaneously is rather challenging. To this end, we directly printed woodpile structures (WSs) utilizing femtosecond laser two-photon polymerization (fs-TPP), which demonstrated obvious SCs under an optical microscope. After that, we achieved the change of SCs by transferring WSs between different mediums. Furthermore, the influence of laser power, structural parameters, and mediums on the SCs was systematically investigated, and the mechanism of SCs using the finite-difference time-domain (FDTD) method was further explored. Finally, we realized the reversible encryption and decryption of certain information. This finding holds broad application prospects in smart sensing, anti-counterfeiting tags, and advanced photonic devices.

3D printing of responsive chiral photonic nanostructures

Finely controlled flow forces in extrusion-based additive manufacturing can be exploited to program the self-assembly of malleable nanostructures in soft materials by integrating bottom-up design into a top-down processing approach. Here, we leverage the processing parameters offered by direct ink-writing (DIW) to reconfigure the photonic chiral nematic liquid crystalline phase in hydroxypropyl cellulose (HPC) solutions prior to deposition on the writing substrate to direct structural evolution from a particular initial condition. Moreover, we incorporate polyethylene glycol (PEG) into iridescent HPC inks to form a physically cross-linked network capable of inducing kinetic arrest of the cholesteric/chiral pitch at length scales that selectively reflect light throughout the visible spectrum. Based on thorough rheological measurements, we have found that printing the chiral inks at a shear rate where HPC molecules adopt pseudonematic state results in uniform chiral recovery following flow cessation and enhanced optical properties in the solid state. Printing chiral inks at high shear rates, on the other hand, shifts the monochromatic appearance of the extruded filaments to a highly angle-dependent state, suggesting a preferred orientation of the chiral domains. The optical response of these filaments when exposed to mechanical deformation can be used in the development of optical sensors.

Hierarchical Organization of Structurally Colored Cholesteric Phases of Cellulose via 3D Printing

Structural color-a widespread phenomenon observed throughout nature is caused by light interference from ordered phases of matter. While state-of-the-art nanofabrication techniques can produce structural organization in small areas, cost-effective and scalable techniques are still lacking to generate tunable color at sub-micron length scales. In this work, structurally colored hydroxypropyl cellulose filaments are produced with a suppressed angular color response by 3D printing. The systematic study of the morphology of the filaments reveals the key stages in the induction of a two-degree hierarchical order through 3D printing. The first degree of order originated from the changing of the cholesteric pitch at a few hundred nm scale via chemical modification and tuning of the solid content of the lyotropic phase. Upon 3D printing, the secondary hierarchical order of periodic wrinkling is introduced through the Helfrich-Hurault deformation of the shear-aligned cholesteric phases. In single-layered filaments, four morphological zones with varying orders of wrinkles are identified. Detailed morphological characterization is carried out using SEM to shed light on the mechanism of the wrinkling behavior. Through this work, the possibility of modifying the wrinkling behavior is demonstrated and thus the angle dependence of the color response by changing the printing conditions.

Complex aspherical singlet and doublet microoptics by grayscale 3D printing

We demonstrate 3D printed aspherical singlet and doublet microoptical components by grayscale lithography and characterize and evaluate their excellent shape accuracy and optical performance. The typical two-photon polymerization (2PP) 3D printing process creates steps in the structure which is undesired for optical surfaces. We utilize two-photon grayscale lithography (2GL) to create step-free lenses. To showcase the 2GL process, the focusing ability of a spherical and aspherical singlet lens are compared. The surface deviations of the aspherical lens are minimized by an iterative design process and no distinct steps can be measured via confocal microscopy. We design, print, and optimize an air-spaced doublet lens with a diameter of 300 µm. After optimization, the residual shape deviation is less than 100 nm for the top lens and 20 nm for the bottom lens of the doublet. We examine the optical performance with an USAF 1951 resolution test chart to find a resolution of 645 lp/mm.

4D Direct Laser Writing of Submerged Structural Colors at the Microscale

Biomimetic stimuli-responsive structure colors (SCs) can improve the visualization and identification in the micro functional structure field such as information encryption/decryption and smart actuators. However, it is still challenging to develop the ability to 4D print arbitrary submerged colorful patterns with stimuli-responsive materials at the microscale. Herein, a hydrogel photoresist with feature resolution (98 nm) for the fabrication of 4D microscopic SCs by the femtosecond direct laser writing method is developed. The 4D printed woodpile SCs are grouped as pixel palettes with various laser parameters and they spanned almost the entire color space. The coloring mechanism of diffraction gratings is not only investigated by optics microscopy and spectroscopy but also supported by simulation. Moreover, the 4D printed hydrogel-integrated amphichromatic fish constructions and pixelated painting can visually discolor reversibly by regulating the solution pH. This finding promises an ideal coloring method for sensors, anti-counterfeiting labels, and transformable photonic devices.

Recent Advances in Printable Flexible Optical Devices: From Printing Technology and Optimization Strategies to Perspectives

Recently, flexible optical devices have triggered booming developments in various research fields, including display equipment, sensors, energy conversion, and so on, due to their high compatibility, portability, and wearability. With the advantages of strong design ability, high precision, and high integration, printing technologies have been recognized as promising methods to realize flexible optical devices. In this Perspective, recent progress on printing strategies for fabricating flexible optical devices are introduced systematically. First, through adjusting the composition of inks, selecting flexible substrates, and controlling external stimulation, fabrication of flexible optical devices based on inkjet printing is illustrated. Then, flexible optical devices fabricated by template-induced printing, 3D printing, slot-die printing, and screen printing are summarized. Finally, prospects and future development directions based on printing technology for flexible optical devices are proposed.

Benzylidene Cyclopentanone Derivative Photoinitiator for Two-Photon Photopolymerization-Photochemistry and 3D Structures Fabrication for X-ray Application

Micron- and submicron-scale 3D structure realization nowadays is possible due to the two-photon photopolymerization (TPP) direct laser writing photolithography (DLW photolithography) method. However, the achievement of lithographic features with dimensions less than 100 nm is in demand for the fabrication of micro-optical elements with high curvature values, including X-ray microlenses. Spectroscopic and photochemical study of a photoinitiator (PI) based on a methyl methacrylate derivative of 2,5-bis(4-(dimethylamino)benzylidene) cyclopentanone was performed. Enhanced intersystem crossing in the methyl methacrylate derivative results in increased radical generation for the subsequent initiation of polymerization. A comprehensive study of the new photocompositions was performed, with particular emphasis on photochemical constants, the degree of photopolymerization, and topology. The optimal parameters for the fabrication of mechanically stable structures were determined in this research. The threshold dose parameters for lithography (radiation power of 5 mW at a speed of 180 µm/s) when trying to reach saturation values with a conversion degree of (35 ± 1) % were defined, as well as parameters for sub-100 nm feature fabrication. Moreover, the 45 nm feature size for elements was reached. Fabrication of X-ray lens microstructures was also demonstrated.

Daytime Sub-Ambient Radiative Cooling with Vivid Structural Colors Mediated by Coupled Nanocavities

Daytime radiative cooling is a promising passive cooling technology for combating global warming. Existing daytime radiative coolers usually show whitish colors due to their high broadband solar reflectivity, which is not suitable for aesthetic demands and effective display. It is challenging to produce high-cooling performance materials with vivid colors because colors are often produced by the absorption of visible light, decreasing net cooling power. In this work, we design a series of colorful multilayered radiative coolers (CMRCs) consisting of an optimized selective emitter for cooling and coupled nanocavities for structural coloration, which can successfully delicately balance the trade-off between the chromaticity and cooling performance. By judiciously designing the geometric parameters and manipulating the coupling effect inside the coupled nanocavities, our coolers show sub-ambient cooling performance and a larger color gamut (occupying 17.7% sRGB area) than reported ones. We further fabricate CMRCs and demonstrate that they have temperature drops of 3.4-4.4 °C on average based on outdoor experiments. These CMRCs are promising in thermal management of electronic/optoelectronic devices and outdoor facilities.

Continuous resin refilling and hydrogen bond synergistically assisted 3D structural color printing

3D photonic crystals (PCs) have attracted extensive attention due to their unique optical properties. However, fabricating 3D PCs structure by 3D printing colloidal particles is limited by control of assembly under a fast-printing speed. Here, we employ continuous digital light processing (DLP) 3D printing strategy with hydrogen bonds assisted colloidal inks for fabricating well-assembled 3D PCs structures. Stable dispersion of colloidal particles inside UV-curable system induced by hydrogen bonding and suction force induced by continuous curing manner cooperatively realize the simultaneous macroscopic printing and microscopic particle assembly, which endows volumetric color property. Structural color can be well regulated by controlling the particle diameter and printing speed, through which various complex 3D structures with desired structural color distribution and optical light-guide properties are acquired. This 3D color construction approach shows great potential in customized jewelry accessories, decoration and optical device preparation, and will innovate the development of structural color.

Full Geometric Control of Hidden Color Information in Diffraction Gratings under Angled White Light Illumination

Under white light illumination, gratings produce an angular distribution of wavelengths dependent on the diffraction order and geometric parameters. However, previous studies of gratings are limited to at least one geometric parameter (height, periodicity, orientation, angle of incidence) kept constant. Here, we vary all geometric parameters in the gratings using a versatile nanofabrication technique, two-photon polymerization lithography, to encode hidden color information through two design approaches. The first approach hides color information by decoupling the effects of grating height and periodicity under normal and oblique incidence. The second approach hides multiple sets of color information by arranging gratings in sectors around semicircular pixels. Different images are revealed with negligible crosstalk under oblique incidence and varying sample rotation angles. Our analysis shows that an angular separation of ≥10° between adjacent sectors is required to suppress crosstalk. This work has potential applications in information storage and security watermarks.

Menezes L, Tittl A, Ren H, Maier SA. Optical Metasurfaces for Energy Conversion

Nanostructured surfaces with designed optical functionalities, such as metasurfaces, allow efficient harvesting of light at the nanoscale, enhancing light-matter interactions for a wide variety of material combinations. Exploiting light-driven matter excitations in these artificial materials opens up a new dimension in the conversion and management of energy at the nanoscale. In this review, we outline the impact, opportunities, applications, and challenges of optical metasurfaces in converting the energy of incoming photons into frequency-shifted photons, phonons, and energetic charge carriers. A myriad of opportunities await for the utilization of the converted energy. Here we cover the most pertinent aspects from a fundamental nanoscopic viewpoint all the way to applications.

Recent Advances in Tunable Metasurfaces: Materials, Design, and Applications

Metasurfaces, a two-dimensional (2D) form of metamaterials constituted by planar meta-atoms, exhibit exotic abilities to tailor electromagnetic (EM) waves freely. Over the past decade, tremendous efforts have been made to develop various active materials and incorporate them into functional devices for practical applications, pushing the research of tunable metasurfaces to the forefront of nanophotonics. Those active materials include phase change materials (PCMs), semiconductors, transparent conducting oxides (TCOs), ferroelectrics, liquid crystals (LCs), atomically thin material, etc., and enable intriguing performances such as fast switching speed, large modulation depth, ultracompactness, and significant contrast of optical properties under external stimuli. Integration of such materials offers substantial tunability to the conventional passive nanophotonic platforms. Tunable metasurfaces with multifunctionalities triggered by various external stimuli bring in rich degrees of freedom in terms of material choices and device designs to dynamically manipulate and control EM waves on demand. This field has recently flourished with the burgeoning development of physics and design methodologies, particularly those assisted by the emerging machine learning (ML) algorithms. This review outlines recent advances in tunable metasurfaces in terms of the active materials and tuning mechanisms, design methodologies, and practical applications. We conclude this review paper by providing future perspectives in this vibrant and fast-growing research field.

Miniature optoelectronic compound eye camera

Inspired by insect compound eyes (CEs) that feature unique optical schemes for imaging, there has recently been growing interest in developing optoelectronic CE cameras with comparable size and functions. However, considering the mismatch between the complex 3D configuration of CEs and the planar nature of available imaging sensors, it is currently challenging to reach this end. Here, we report a paradigm in miniature optoelectronic integrated CE camera by manufacturing polymer CEs with 19~160 logarithmic profile ommatidia via femtosecond laser two-photon polymerization. In contrast to μ-CEs with spherical ommatidia that suffer from defocusing problems, the as-obtained μ-CEs with logarithmic ommatidia permit direct integration with a commercial CMOS detector, because the depth-of-field and focus range of all the logarithmic ommatidia are significantly increased. The optoelectronic integrated μ-CE camera enables large field-of-view imaging (90°), spatial position identification and sensitive trajectory monitoring of moving targets. Moreover, the miniature μ-CE camera can be integrated with a microfluidic chip and serves as an on-chip camera for real-time microorganisms monitoring. The insect-scale optoelectronic μ-CE camera provides a practical route for integrating well-developed planar imaging sensors with complex micro-optics elements, holding great promise for cutting-edge applications in endoscopy and robot vision.

Photonic bandgap engineering in hybrid one-dimensional photonic crystals containing all-dielectric elliptical metamaterials

Metamaterials with negative permittivities or/and permeabilities greatly enrich photonic bandgap (PBG) engineering in one-dimensional (1-D) photonic crystals (PhCs). Nevertheless, their inevitable optical losses strongly destroy the crucial prohibition characteristic of PBGs, which makes such engineered PBGs not utilizable in some relevant physical processes and optical/optoelectronic devices. Herein, we bridge a link between 1-D PhCs and all-dielectric loss-free metamaterials and propose a hybrid 1-D PhC containing all-dielectric elliptical metamaterials to engineer angle-dependence of PBGs. Associating the Bragg scattering theory with the iso-frequency curve analysis, an analytical model is established to precisely describe the angle-dependence of PBG. Based on the analytical model, two types of special PBGs, i.e., angle-insensitive and angle-sensitive PBGs, are designed. By further introducing defects into the designed 1-D PhCs, angle-dependence of defect modes can also be flexibly controlled. Our protocol opens a viable route to precisely engineering PBGs and promotes the development of PBG-based physics and applications.

Electrically switchable structural colors based on liquid-crystal-overlaid aluminum anisotropic nanoaperture arrays

Actively tunable or reconfigurable structural colors are highly promising in future development for high resolution imaging and displaying applications. To this end, we demonstrate switchable structural colors covering the entire visible range by integrating aluminum nanoaperture arrays with nematic liquid crystals. The geometrically anisotropic design of the nanoapertures provides strong polarization-dependent coloration. By overlaying a nematic liquid crystal layer, we further demonstrate switchable ability of the structural colors by either changing the polarization of the incident light or applying an external voltage. The switchable structural colors have a fast response time of 28 ms at a driving voltage of 6.5 V. Furthermore, colorful patterns are demonstrated by coding the colors with various dimensions of nanoaperture arrays with dual switching modes. Our proposed technique in this work provides a dual-mode switchable structural colors, which is highly promising for polarimetric displays, imaging sensors, and visual cryptography.

3D printing colloidal crystal microstructures via sacrificial-scaffold-mediated two-photon lithography

The orderly arrangement of nanomaterials’ tiny units at the nanometer-scale accounts for a substantial part of their remarkable properties. Maintaining this orderness and meanwhile endowing the nanomaterials with highly precise and free-designed 3D micro architectures will open an exciting prospect for various novel applications. In this paper, we developed a sacrificial-scaffold-mediated two-photon lithography (TPL) strategy that enables the fabrication of complex 3D colloidal crystal microstructures with orderly-arranged nanoparticles inside. We show that, with the help of a degradable hydrogel scaffold, the disturbance effect of the femtosecond laser to the nanoparticle self-assembling could be overcome. Therefore, hydrogel-state and solid-state colloidal crystal microstructures with diverse compositions, free-designed geometries and variable structural colors could be easily fabricated. This enables the possibility to create novel colloidal crystal microsensing systems that have not been achieved before.

Colloidal crystals are widely applied in the fabrication of optoelectronic devices, but realizing freedom of design, such as in 3D printing, in colloidal crystal fabrication remains challenging. Here, the authors demonstrate a sacrificial-scaffold-mediated two-photon lithography strategy that enables the fabrication of complex 3D colloidal crystal microstructures with orderly arranged nanoparticles in the bulk.

Three-dimensional printing of photonic colloidal glasses into objects with isotropic structural color

Structural color is frequently exploited by living organisms for biological functions and has also been translated into synthetic materials as a more durable and less hazardous alternative to conventional pigments. Additive manufacturing approaches were recently exploited for the fabrication of exquisite photonic objects, but the angle-dependence observed limits a broader application of structural color in synthetic systems. Here, we propose a manufacturing platform for the 3D printing of complex-shaped objects that display isotropic structural color generated from photonic colloidal glasses. Structurally colored objects are printed from aqueous colloidal inks containing monodisperse silica particles, carbon black, and a gel-forming copolymer. Rheology and Small-Angle-X-Ray-Scattering measurements are performed to identify the processing conditions leading to printed objects with tunable structural colors. Multimaterial printing is eventually used to create complex-shaped objects with multiple structural colors using silica and carbon as abundant and sustainable building blocks.

There is a growing interest in mimicking structural color in natural systems aiming for sustainable and long-lasting color. Here the authors report a platform for three-dimensional printing assembly of colloidal particles of silica and carbon that have programmable structural color.

Tunable structural colors in all-dielectric photonic crystals using energetic ion beams

The modulation of structural color through various methods has attracted considerable attention. Herein, a new modulation method for the structural colors in all-dielectric photonic crystals (PCs) using energetic ion beams is proposed. One type of periodic PC and two different defective PCs were experimentally investigated. Under carbon-ion irradiation, the color variation primarily originated from the blue shift of the optical spectra. The varying degrees of both the reflection and transmission structural colors mainly depended on the carbon-ion fluences. Such nanostructures are promising for tunable color filters and double-sided chromatic displays based on PCs.

Cholesteric cellulose liquid crystal ink for three-dimensional structural coloration

SignificanceWe propose a printable structural color ink composed of cholesteric cellulose liquid crystals together with gelatin and a thermal-responsive hydrogel. The ink is endowed with vivid structural colors and printability due to its constituents. Based on this, we print a series of graphics and three-dimensional (3D) objects with vivid color appearances. Moreover, the printed objects possess dual thermal responsiveness, which results in visible color change around body temperature. These performances, together with the biocompatibility of the constituents, indicate that the present ink represents a leap forward to the next-generation 3D printing and would unlock a wide range of real-life applications.

High-Order Photonic Cavity Modes Enabled 3D Structural Colors

It remains a challenge to directly print arbitrary three-dimensional shapes that exhibit structural colors at the micrometer scale. Woodpile photonic crystals (WPCs) fabricated via two-photon lithography (TPL) are elementary building blocks to produce 3D geometries that generate structural colors due to their ability to exhibit either omnidirectional or anisotropic photonic stop bands. However, existing approaches produce structural colors on WPCs when illuminating from the top, requiring print resolutions beyond the limit of commercial TPL, which necessitates postprocessing techniques. Here, we devised a strategy to support high-order photonic cavity modes upon side illumination on WPCs that surprisingly generate prominent reflectance peaks in the visible spectrum. Based on that, we demonstrate one-step printing of 3D photonic structural colors without requiring postprocessing or subwavelength features. Vivid colors with reflectance peaks exhibiting a full width at half-maximum of ∼25 nm, a maximum reflectance of 50%, a gamut of ∼85% of sRGB, and large viewing angles were achieved. In addition, we also demonstrated voxel-level manipulation and control of colors in arbitrary-shaped 3D objects constituted with WPCs as unit cells, which has potential for applications in dynamic color displays, colorimetric sensing, anti-counterfeiting, and light-matter interaction platforms.

Beyond the Threshold: A Study of Chalcogenophene-Based Two-Photon Initiators

A series of nine soluble, symmetric chalcogenophenes bearing hexyl-substituted triphenylamines, indolocarbazoles, or phenylcarbazoles was designed and synthesized as potential two-photon absorption (2PA) initiators. A detailed photophysical analysis of these molecules revealed good 2PA properties of the series and, in particular, a strong influence of selenium on the 2PA cross sections, rendering these materials especially promising new 2PA photoinitiators. Structuring and threshold tests proved the efficiency and broad spectral versatility of two selenium-containing lead compounds as well as their applicability in an acrylate resin formulation. A comparison with commercial photoinitiators Irg369 and BAPO as well as sensitizer ITX showed that the newly designed selenium-based materials TPA-S and TPA-BBS outperform these traditional initiators by far both in terms of reactivity and dose. Moreover, by increasing the ultralow concentration of TPA-BBS, a further reduction of the polymerization threshold can be achieved, revealing the great potential of this series for application in two-photon polymerization (2PP) systems where only low laser power is available.

Recent Progress in Responsive Structural Color

Structural color has been regarded as an ideal alternative to pigments because of the advantages of environmental friendliness, resistance to fading, and dynamic regulation. Responsive structural color can give real-time visible feedback to external stimuli and thus has great prospects in many applications, such as displays, sensing, anticounterfeiting, information storage, and healthcare monitoring. In this Perspective, we elucidate basic concepts, controllable fabrications, and promising applications of responsive structural colors. In particular, we systematically summarize the general regulation mode of all kinds of responsive structural color systems. First, we introduce the basic chromogenic structures as well as the regulation modes of responsive structural color. Second, we present the fabrication methods of patterned structural color. Then, the promising applications of responsive structural color systems are highlighted in detail. Finally, we present the existing challenges and future perspectives on responsive structural colors.

A Biomimetic Human Lung-on-a-Chip with Colorful Display of Microphysiological Breath

Lung-on-a-chip models hold great promise for disease modeling and drug screening. Herein, inspired by the iridescence phenomenon of soap bubbles, a novel biomimetic 3D microphysiological lung-on-a-chip system with breathing visualization is presented. The system, with an array of pulmonary alveoli at the physiological scale, is constructed and coated with structural color materials. Cyclic deformation is induced by regular airflow, resembling the expansion and contraction of the alveoli during rhythmic breathing. As the deformation is accompanied with corresponding synchronous shifts in the structural color, the constructed system offers self-reporting of the cell mechanics and enables real-time monitoring of the cultivation process. Using this system, the dynamic relationships between the color atlas and disease symptoms, showing the essential role of mechanical stretching in the phenotypes of idiopathic pulmonary fibrosis, are investigated. These features make this human lung system ideal in biological study, disease monitoring, and drug discovery.

Metasurface-empowered spectral and spatial light modulation for disruptive holographic displays

The holographic display, one of the most realistic ways to reconstruct optical images in three-dimensional (3D) space, has gained a lot of attention as a next-generation display platform for providing deeper immersive experiences to users. So far, diffractive optical elements (DOEs) and spatial light modulators (SLMs) have been used to generate holographic images by modulating electromagnetic waves at each pixel. However, such architectures suffer from limitations in terms of having a resolution of only a few microns and the bulkiness of the entire optical system. In this review, we describe novel metasurfaces-based nanophotonic platforms that have shown exceptional control of electromagnetic waves at the subwavelength scale as promising candidates to overcome existing restrictions, while realizing flat optical devices. After introducing the fundamentals of metasurfaces in terms of spatial and spectral wavefront modulation, we present a variety of multiplexing approaches for high-capacity and full-color metaholograms exploiting the multiple properties of light as an information carrier. We then review tunable metaholograms using active materials modulated by several external stimuli. Afterward, we discuss the integration of metasurfaces with other optical elements required for future 3D display platforms in augmented/virtual reality (AR/VR) displays such as lenses, beam splitters, diffusers, and eye-tracking sensors. Finally, we address the challenges of conventional nanofabrication methods and introduce scalable preparation techniques that can be applied to metasurface-based nanophotonic technologies towards commercially and ergonomically viable future holographic displays.

λ/30 inorganic features achieved by multi-photon 3D lithography

It’s critically important to construct arbitrary inorganic features with high resolution. As an inorganic photoresist, hydrogen silsesquioxane (HSQ) has been patterned by irradiation sources with short wavelength, such as EUV and electron beam. However, the fabrication of three- dimensional nanoscale HSQ features utilizing infrared light sources is still challenging. Here, we demonstrate femtosecond laser direct writing (FsLDW) of HSQ through multi-photon absorption process. 26 nm feature size is achieved by using 780 nm fs laser, indicating super-diffraction limit photolithography of λ/30 for HSQ. HSQ microstructures by FsLDW possess nanoscale resolution, smooth surface, and thermal stability up to 600 °C. Furthermore, we perform FsLDW of HSQ to construct structural colour and Fresnel lens with desirable optical properties, thermal and chemical resistance. This study demonstrates that inorganic features can be flexibly achieved by FsLDW of HSQ, which would be prospective for fabricating micro-nano devices requiring nanoscale resolution, thermal and chemical resistance.

Stereolithography has progressed over the years but resolution and feature size is still limited by the properties of materials and resins. Here, the authors demonstrate femtosecond laser direct writing of a hydrogen silsesquioxane photoresist using a 780 nm femtosecond laser demonstrating feature sizes of 26 nm.

NIR-Reflective and Hydrophobic Bio-Inspired Nano-Holed Configurations on Titanium Alloy

Near-infrared (NIR) radiation plays an important role in guided external stimulus therapies; its application in bone-related treatments is becoming more and more frequent. Therefore, metallic biomaterials that exhibit properties activated by NIR are promising for further orthopedic procedures. In this work, we present an adapted electroforming approach to attain a biomorphic nano-holed TiO₂ coating on Ti6Al4V alloy. Through a precise control of the anodization conditions, structures revealed the formation of localized nano-pores arranged in a periodic assembly. This specific organization provoked higher stability against thermal oxidation and precise hydrophobic wettability behavior according to Cassie-Baxter's model; both characteristics are a prerequisite to ensure a favorable biological response in an implantable structure for guided bone regeneration. In addition, the periodically arranged sub-wavelength-sized unit cell on the metallic-dielectric structure exhibits a peculiar optical response, which results in higher NIR reflectivity. Accordingly, we have proved that this effect enhances the efficiency of the scattering processes and provokes a significant improvement of light confinement producing a spontaneous NIR fluorescence emission. The combination of the already favorable mechanical and biocompatibility properties of Ti6Al4V, along with suitable thermal stability, wetting, and electro-optical behavior, opens a promising path toward strategic bone therapeutic procedures.

Co-Assembly of Biosynthetic Chiral Nematic Adhesive Materials with Dynamic Polarized Luminescence

There is currently an extensive demand for simple and effective synthetic methods to allow the design and fabrication of robust and flexible chiral materials that can generate strong and switchable circularly polarized luminescence (CPL). Herein, biosynthetic light-emitting adhesive materials based upon chiral nematic cellulose nanocrystal-polyelectrolyte complexes with universal high adhesion on both hydrophilic and hydrophobic substrates are reported. Strong and dynamic photoluminescence with highly asymmetric and switchable circular polarization is induced by minute rare earth europium doping without compromising adhesive strength and initial iridescent properties. The photoluminescence can be temporarily quenched with highly volatile acetone vapor and liquid followed by fast recovery after drying with full restoration of initial emission. The unique properties of light-emitting bio-adhesives with universal adhesion, amplified and dynamic photoluminescence, and large and switchable CPL can be utilized for security optical coding, bio-optical memory, hidden communication, and biochemical sensing as wearable stickers, prints, and tattoos to directly adhere to human clothes, gadgets, and skin by using adhesive stickers with bright tailored photoluminescence.

Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses

3D printing has been considered as a sustainable method to construct complicated 3D structures. However, the step effect induced by the traditional point-by-point or layer-by-layer additive manufacturing mode inevitably occurs and remains an obstacle to realizing the smoothness and uniformity of 3D samples. Here, a continuous liquid film confined 3D printing strategy is proposed to fabricate high-precision 3D structures based on the Digital Light Processing (DLP) technology. With the control of the confinement of the liquid-solid interface and the continuous printing mode, liquid film adhering to the cured structure is sucked into the cured layer structures with excess resin adhering to the cured structure scraping off, where the step effect is eliminated and post-washing is avoided. The morphology and dimension of the confined liquid film can be well regulated by ink properties and printing parameters to optimize the surface smoothness and printing fidelity. In addition, heat accumulation and thermal diffusion are also suppressed, ensuring the long-term printing stability. A centimeter-scale contact lens structure with central thickness of ≈135 µm comparable to commercial ones can be printed, which possesses extreme smoothness (sub 1.3 nm), homogeneous mechanical characteristic, biocompatibility, and high optical properties with imaging resolution of up to 228.1 lp mm^-1 .