Volumetric additive manufacturing of silica glass with microscale computed axial lithography

Hybrid Plasmonic Bioresins and dECM-Based Materials for Volumetric Bioprinting of Vascular-Inspired Architectures

Synergizing nanomaterial technology with advanced 3D printing techniques creates new opportunities for developing smart, stimuli-responsive materials suitable for tissue engineering scaffolds. By incorporation of stimuli-responsive nanoparticles into extracellular matrix mimetics, these composites gain functional elements capable of replicating dynamic biological processes in vitro. Herein, we propose combining hybrid multifunctional inorganic-organic materials with the emerging volumetric bioprinting (VBP) technique. We present two hybrid materials, a light stimuli-responsive polymer-based resin and a biocompatible porcine-derived decellularized extracellular matrix (dECM)-based bioresin, thus expanding the library of materials suitable for VBP. Plasmonic nanoparticles are combined with a thermoresponsive polymeric matrix, formulating the stimuli-responsive plasmonic resin, while a dECM-based bioresin with embedded smooth muscle cells (SMCs) is employed to include the biological component in the system. As proof of concept to demonstrate the versatility of the hybrid materials, we investigated the generation of highly complex structures, including multiwalled channels, using sequential VBP. Overall, this study broadens the range of materials compatible with VBP, thereby enabling the use of smart multicomponent materials in the fabrication of dynamic, stimuli-responsive 3D in vitro models.

Hybrid Formative-Additive Manufacturing

Material extrusion additive manufacturing (AM) provides extensive design flexibility and exceptional material versatility, enabling the fabrication of complex, multifunctional objects ranging from embedded electronics to soft robotics and vascularized tissues. The bottom-up creation of these objects typically requires discretization into layers and voxels. However, the voxel size, determined by the nozzle diameter, limits extrusion rate, creating a conflict between resolution and speed. To address these inherent scalability challenges, the study proposes a hybrid formative-additive manufacturing technology that combines the respective strengths of each method-speed and quality with complexity and flexibility. The approach involves 3D-printing complex geometries, multimaterial features, and bounding walls of bulky, lower-resolution volumes, which are rapidly filled via casting or molding. By precisely controlling the materials' rheological properties-while maintaining similar solidified properties and high interfacial strength-several typical AM flaws, such as bulging and internal voids, are eliminated, achieving exponentially faster production speeds for objects with varying feature sizes.

General and Versatile Nanoarchitectonics for Amino Acid-Based Glasses via Co-Assembly of Organic Counterions

Amino acid-based biomolecular glasses represent an emerging material to meet the demand for sustainable development. However, most amino acids are difficult to vitrify due to their strong crystallization tendency, limiting further advancements of this field. In this study, we demonstrate that the introduction of counterions effectively suppresses crystallization, as hydrogen bonds within the system stabilize the disordered structures. Based on this, we propose a counterion co-assembly strategy to synthesize a wide range of amino acid-based glasses. This strategy enables the facile fabrication of glass with customizable shapes, high mechanical rigidity, and tunable multicolor fluorescence, ranging from blue to red depending on the excitation wavelength. Furthermore, this strategy allows the integration and enhancement of counterion properties within the glass matrix. Through the co-assembly of phosphorescent counterions, we synthesized a series of long-persistent luminescent glasses with significantly extended afterglow lifetimes. This work presents an effective approach for the synthesis of amino acid-based glasses and provides insights into the development of supramolecular glasses with tailored functionalities.

Multi-material Gradient Printing Using Meniscus-enabled Projection Stereolithography (MAPS)

Light-based additive manufacturing methods have been widely used to print high-resolution 3D structures for applications in tissue engineering, soft robotics, photonics, and microfluidics, among others. Despite this progress, multi-material printing with these methods remains challenging due to constraints associated with hardware modifications, control systems, cross-contamination, waste, and resin properties. Here, we report a new printing platform coined Meniscus-enabled Projection Stereolithography (MAPS), a vat-free method that relies on generating and maintaining a resin meniscus between a crosslinked structure and bottom window to print lateral, vertical, discrete, or gradient multi-material 3D structures with no waste and user-defined mixing between layers. We show that MAPS is compatible with a wide range of resins and can print complex multi-material 3D structures without requiring specialized hardware, software, or complex washing protocols. MAPS's ability to print structures with microscale variations in mechanical stiffness, opacity, surface energy, cell densities, and magnetic properties provides a generic method to make advanced materials for a broad range of applications.

Rapid fabrication of highly uniform polygons by femtosecond laser patterning based on free lens modulation

Structured light featuring multiple customizable degrees of freedom has become a powerful tool for femtosecond laser processing, enabling much higher throughput and considerable finesse and flexibility. A non-iterative beam shaping technique avoids solving inversion problems of light propagation, but the types of available beam profiles are finite. Here, a phase-only method that can prescribe the beam intensity along an arbitrary two-dimensional curve, called free lens modulation, is applied in femtosecond laser patterned exposure. Single polygonal microstructures with diverse morphology and high surface quality can be fabricated in less than 1 s while outperforming common iterative algorithms in contour fidelity. Moreover, a microfluidic device with a filtering function is designed and demonstrated by integrating microtrap arrays composed of polygons into a microchannel based on the holographic approach. The method offers new inspiration for the rapid construction of large-area microfluidic devices and integrated microsystems with customizable functional applications.

High-resolution bioprinting of complex bio-structures via engineering of the photopatterning approaches and adaptive segmentation

Digital light processing (DLP) technology has significantly advanced various applications, including 3D bioprinting, through its precision and speed in creating detailed structures. While traditional DLP systems rely on light-emitting diodes (LEDs), their limited power spectral density, high etendue, and spectral inefficiency constrain their performance in resolution, dynamic range, printing time, and cell viability. This study proposes and evaluates a dual-laser DLP system to overcome these limitations and enhance bioprinting performance. The proposed dual-laser system resulted in a twofold increase in resolution and a twelvefold reduction in printing time compared to the LED system. The system's capability was evaluated by printing three distinct designs, achieving a maximum percentage error of 1.16% and a minimum of 0.02% in accurately reproducing complex structures. Further, the impact of exposure times (10-30 s) and light intensities (0.044-0.11 mW mm-2) on the viability and morphology of 3T3 fibroblasts in GelMA and GelMA-poly(ethylene glycol) diacrylate (PEGDA) hydrogels is assessed. The findings reveal a clear relationship between longer exposure times and reduced cell viability. On day 7, samples exposed for extended periods exhibited the lowest metabolic activity and cell density, with differences of ∼40% between treatments. However, all samples show recovery by day 7, with GelMA samples exhibiting up to a sixfold increase in metabolic activity and GelMA-PEGDA samples showing up to a twofold increase. In contrast, light intensity variations had a lesser effect, with a maximum variation of 15% in cell viability. We introduced a segmented printing method to mitigate over-crosslinking and enhance the dynamic range, utilizing an adaptive segmentation control strategy. This method, demonstrated by printing a bronchial model with a 14.43x compression ratio, improved resolution and maintained cell viability up to 90% for GelMA and 85% for GelMA-PEGDA during 7 d of culture. The proposed dual-laser system and adaptive segmentation method were confirmed through successful prints with diverse bio-inks and complex structures, underscoring its advantages over traditional LED systems in advancing 3D bioprinting.

3D printing of micro-nano devices and their applications

In recent years, the utilization of 3D printing technology in micro and nano device manufacturing has garnered significant attention. Advancements in 3D printing have enabled achieving sub-micron level precision. Unlike conventional micro-machining techniques, 3D printing offers versatility in material selection, such as polymers. 3D printing technology has been gradually applied to the general field of microelectronic devices such as sensors, actuators and flexible electronics due to its adaptability and efficacy in microgeometric design and manufacturing processes. Furthermore, 3D printing technology has also been instrumental in the fabrication of microfluidic devices, both through direct and indirect processes. This paper provides an overview of the evolving landscape of 3D printing technology, delineating the essential materials and processes involved in fabricating microelectronic and microfluidic devices in recent times. Additionally, it synthesizes the diverse applications of these technologies across different domains.

Holographic tomographic volumetric additive manufacturing

Several 3D light-based printing technologies have been developed that rely on the photopolymerization of liquid resins. A recent method, so-called Tomographic Volumetric Additive Manufacturing, allows the fabrication of microscale objects within tens of seconds without the need for support structures. This method works by projecting intensity patterns, computed via a reverse tomography algorithm, into a photocurable resin from different angles to produce a desired 3D shape when the resin reaches the polymerization threshold. Printing using incoherent light patterning has been previously demonstrated. In this work, we show that a light engine with holographic phase modulation unlocks new potential for volumetric printing. The light projection efficiency is improved by at least a factor 20 over amplitude coding with diffraction-limited resolution and its flexibility allows precise light control across the entire printing volume. We show that computer-generated holograms implemented with tiled holograms and point-spread-function shaping mitigates the speckle noise which enables the fabrication of millimetric 3D objects exhibiting negative features of 31 μm in less than a minute with a 40 mW light source in acrylates and scattering materials, such as soft cell-laden hydrogels, with a concentration of 0.5 million cells per mL.

Bio-Informed Porous Mineral-Based Composites

Certain biominerals, such as sea sponges and echinoderm skeletons, display a fascinating combination of mechanical properties and adaptability due to the well-defined structures spanning various length scales. These materials often possess high density normalized mechanical properties because they contain well-defined pores. The density-normalized mechanical properties of synthetic minerals are often inferior because the pores are stochastically distributed, resulting in an inhomogeneous stress distribution. The mechanical properties of synthetic materials are limited by the degree of structural and compositional control currently available fabrication methods offer. In the first part of this review, examples of structural elements nature uses to impart exceptional density normalized Young's moduli to its porous biominerals are showcased. The second part highlights recent advancements in the fabrication of bio-informed mineral-based composites possessing pores with diameters that span a wide range of length scales. The influence of the processing of mineral-based composites on their structures and mechanical properties is summarized. Thereby, it is aimed at encouraging further research directed to the sustainable, energy-efficient fabrication of synthetic lightweight yet stiff mineral-based composites.

Elucidating Photochemical Conversion Mechanism of PDMS to Silica under Deep UV Light and Ozone

Photochemistry-based silica formation offers a pathway toward energy-efficient and controlled fabrication processes. While the transformation of poly(dimethylsiloxane) (PDMS) to silica (often referred to as SiOx due to incomplete conversion) under deep ultraviolet (DUV) irradiation in the presence of oxygen/ozone has experimentally been validated, the detailed mechanism remains elusive. This study demonstrates the underlying molecular-level mechanism of PDMS-to-silica conversion using density functional theory (DFT) calculations. Our findings reveal that atomic oxygen plays a key role in converting PDMS to silica by catalyzing the replacement of -CH3 groups to -OH groups, with a barrier-less insertion into Si-C and C-H bonds, eventually leading to condensation reactions that produce silica and formaldehyde and/or formic acid as byproducts. The proposed molecular pathway has further been validated through controlled experiments, which confirm the successive -CH3 to -OH replacements and identify gaseous byproducts such as formaldehyde. These findings offer insights into the fundamental processes involved in photochemistry-based silica fabrication and could pave the way for advancements in energy-efficient materials synthesis.

Volumetric Additive Manufacturing for Cell Printing: Bridging Industry Adaptation and Regulatory Frontiers

Volumetric additive manufacturing (VAM) is revolutionizing the field of cell printing by enabling the rapid creation of complex three-dimensional cellular structures that mimic natural tissues. This paper explores the advantages and limitations of various VAM techniques, such as holographic lithography, digital light processing, and volumetric projection, while addressing their suitability across diverse industrial applications. Despite the significant potential of VAM, challenges related to regulatory compliance and scalability persist, particularly in the context of bioprinted tissues. In India, the lack of clear regulatory guidelines and intellectual property protections poses additional hurdles for companies seeking to navigate the evolving landscape of bioprinting. This study emphasizes the importance of collaboration among industry stakeholders, regulatory agencies, and academic institutions to establish tailored frameworks that promote innovation while ensuring safety and efficacy. By bridging the gap between technological advancement and regulatory oversight, VAM can unlock new opportunities in regenerative medicine and tissue engineering, transforming patient care and therapeutic outcomes.

Bio-sourced flexible supramolecular glasses for dynamic and full-color phosphorescence

Glass, a diverse family of amorphous materials, has significantly advanced human society across various fields. The demand for flexible ultrathin glass, driven by modern optical displays and portable optoelectronics, presents challenges in energy consumption, fabrication complexity, and recycling. Here, we demonstrate flexibility and full-color luminescence in large-scale ultrathin glasses derived from readily available natural resources, specifically egg albumen (EA) and gelatin (GEL), via an evaporation-driven self-assembly process. The dynamic crosslinked networks formed through hydrogen bonding between EA and GEL impart both high hardness and flexibility to the glasses, with hardness and flexural strength values comparable to state-of-the-art inorganic and organic glasses. Additionally, the EA-GEL-based glasses exhibit excitation-dependent and time-gated chiral ultralong phosphorescence with color from blue and red, and a lifetime of up to 180.4 ms. With their easy processability and full-color emission, these biogenic glasses can be fabricated into anti-counterfeiting patterns and optical information codes.

High-Resolution Structuring of Silica-Based Nanocomposites for the Fabrication of Transparent Multicomponent Glasses with Adjustable Properties

Silicate-based multicomponent glasses are of high interest for technical applications due to their tailored properties, such as an adaptable refractive index or coefficient of thermal expansion. However, the production of complex structured parts is associated with high effort, since glass components are usually shaped from high-temperature melts with subsequent mechanical or chemical postprocessing. Here for the first time the fabrication of binary and ternary multicomponent glasses using doped nanocomposites based on silica nanoparticles and photocurable metal oxide precursors as part of the binder matrix is presented. The doped nanocomposites are structured in high resolution using UV-casting and additive manufacturing techniques, such as stereolithography and two-photon lithography. Subsequently, the composites are thermally converted into transparent glass. By incorporating titanium oxide, germanium oxide, or zirconium dioxide into the silicate glass network, multicomponent glasses are fabricated with an adjustable refractive index nD between 1.4584-1.4832 and an Abbe number V of 53.85-61.13. It is further demonstrated that by incorporating 7 wt% titanium oxide, glasses with ultralow thermal expansion can be fabricated with so far unseen complexity. These novel materials enable for the first time high-precision lithographic structuring of multicomponent silica glasses with applications from optics and photonics, semiconductors as well as sensors.

Design of Shape Forming Elements for Architected Composites via Bayesian Optimization and Genetic Algorithms: A Concept Evaluation

This article presents the first use of shape forming elements (SFEs) to produce architected composites from multiple materials in an extrusion process. Each SFE contains a matrix of flow channels connecting input and output ports, where materials are routed between corresponding ports. The mathematical operations of rotation and shifting are described, and design automation is explored using Bayesian optimization and genetic algorithms to select fifty or more parameters for minimizing two objective functions. The first objective aims to match a target cross-section by minimizing the pixel-by-pixel error, which is weighted with the structural similarity index (SSIM). The second objective seeks to maximize information content by minimizing the SSIM relative to a white image. Satisfactory designs are achieved with better objective function values observed in rectangular rather than square flow channels. Validation extrusion of modeling clay demonstrates that while SFEs impose complex material transformations, they do not achieve the material distributions predicted by the digital model. Using the SSIM for results comparison, initial stages yielded SSIM values near 0.8 between design and simulation, indicating a good initial match. However, the control of material processing tended to decline with successive SFE processing with the SSIM of the extruded output dropping to 0.023 relative to the design intent. Flow simulations more closely replicated the observed structures with SSIM values around 0.4 but also failed to predict the intended cross-sections. The evaluation highlights the need for advanced modeling techniques to enhance the predictive accuracy and functionality of SFEs for biomedical, energy storage, and structural applications.

Dynamic interface printing

Additive manufacturing is an expanding multidisciplinary field encompassing applications including medical devices1, aerospace components2, microfabrication strategies3,4 and artificial organs5. Among additive manufacturing approaches, light-based printing technologies, including two-photon polymerization6, projection micro stereolithography7,8 and volumetric printing9-14, have garnered significant attention due to their speed, resolution or potential applications for biofabrication. Here we introduce dynamic interface printing, a new 3D printing approach that leverages an acoustically modulated, constrained air-liquid boundary to rapidly generate centimetre-scale 3D structures within tens of seconds. Unlike volumetric approaches, this process eliminates the need for intricate feedback systems, specialized chemistry or complex optics while maintaining rapid printing speeds. We demonstrate the versatility of this technique across a broad array of materials and intricate geometries, including those that would be impossible to print with conventional layer-by-layer methods. In doing so, we demonstrate the rapid fabrication of complex structures in situ, overprinting, structural parallelization and biofabrication utility. Moreover, we show that the formation of surface waves at the air-liquid boundary enables enhanced mass transport, improves material flexibility and permits 3D particle patterning. We, therefore, anticipate that this approach will be invaluable for applications where high-resolution, scalable throughput and biocompatible printing is required.

Volumetric Additive Manufacturing of SiOC by Xolography

Additive manufacturing (AM) of ceramics has significantly contributed to advancements in ceramic fabrication, solving some of the difficulties of conventional ceramic processing and providing additional possibilities for the structure and function of components. However, defects induced by the layer-by-layer approach on which traditional AM techniques are based still constitute a challenge to address. This study presents the volumetric AM of a SiOC ceramic from a preceramic polymer using xolography, a linear volumetric AM process that allows to avoid the staircase effect typical of other vat photopolymerization techniques. Besides optimizing the trade-off between preceramic polymer content and transmittance, a pore generator is introduced to create transient channels for gas release before decomposition of the organic constituents and moieties, resulting in crack-free solid ceramic structures even at low ceramic yield. Formulation optimization alleviated sinking of printed parts during printing and prevented shape distortion. Complex solid and porous ceramic structures with a smooth surface and sharp features are fabricated under the optimized parameters. This work provides a new method for the AM of ceramics at µm/mm scale with high surface quality and large geometry variety in an efficient way, opening the possibility for applications in fields such as micromechanical systems and microelectronic components.

Solvent-Free Silsesquioxane Self-Welding for 3D Printing Multi-Refractive Index Glass Objects

The growing interest in 3D printing of silica glass has spurred substantial research efforts. Our prior work utilizing a liquid silica resin (LSR) demonstrated high printing accuracy and resolution. However, the resin's sensitivity to moisture posed limitations, restricting the printing environment. On the other hand, polyhedral oligomeric silsesquioxane (POSS)-based materials offer excellent water stability and sinterless features. Yet, they suffer from relatively high shrinkage due to the presence of additional organic monomers. In this study, we present a polymeric silsesquioxane (PSQ) resin with reduced shrinkage, enhanced moisture stability, and the retention of sinterless features, providing a promising solution for achieving high-resolution 3D printing of glass objects. Leveraging the two-photon polymerization (2PP) method, we realized nanostructures with feature sizes below 80 nm. Moreover, we demonstrate the tunability of the refractive index by incorporating zirconium moieties into the resin, facilitating the fabrication of glass micro-optics with varying refractive indices. Importantly, the self-welding capability observed between two individual components provides a flexible approach for producing micro-optics with multiple components, each possessing distinct refractive indices. This research represents a significant advancement in the field of advanced glass manufacturing, paving the way for future applications in micro- and nano-scale glass objects.

Ultrafast Laser 3D Nanolithography of Fiber-Integrated Silica Microdevices

Fiber-integrated micro/nanostructures play a crucial role in modern industry, mainly owing to their compact size, high sensitivity, and resistance to electromagnetic interference. However, the three-dimensional manufacturing of fiber-tip functional structures beyond organic polymers remains challenging. It is essential to construct fiber-integrated inorganic silica with designed functional nanostructures for microsystem applications. Here, we develop a strategy for the 3D nanolithography of fiber-integrated silica from hybrid organic-inorganic materials by ultrafast laser-induced multiphoton absorption. Without silica nanoparticles and polymer additives, the acrylate-functionalized precursors can be locally cross-linked through a nonlinear effect. Followed by annealing at low temperature, the as-printed micro/nanostructures are transformed to high-quality silica with sub-100 nm resolution. Silica microcantilever probes and microtoroid resonators are directly integrated onto the optical fiber, showing strong thermal stability and quality factors. This work provides a promising strategy for fabricating desired fiber-tip silica micro/nanostructures, which is helpful for the development of integrated functional device applications.

Rapid Volumetric Bioprinting of Decellularized Extracellular Matrix Bioinks

Decellularized extracellular matrix (dECM)-based hydrogels are widely applied to additive biomanufacturing strategies for relevant applications. The extracellular matrix components and growth factors of dECM play crucial roles in cell adhesion, growth, and differentiation. However, the generally poor mechanical properties and printability have remained as major limitations for dECM-based materials. In this study, heart-derived dECM (h-dECM) and meniscus-derived dECM (Ms-dECM) bioinks in their pristine, unmodified state supplemented with the photoinitiator system of tris(2,2-bipyridyl) dichlororuthenium(II) hexahydrate and sodium persulfate, demonstrate cytocompatibility with volumetric bioprinting processes. This recently developed bioprinting modality illuminates a dynamically evolving light pattern into a rotating volume of the bioink, and thus decouples the requirement of mechanical strengths of bioprinted hydrogel constructs with printability, allowing for the fabrication of sophisticated shapes and architectures with low-concentration dECM materials that set within tens of seconds. As exemplary applications, cardiac tissues are volumetrically bioprinted using the cardiomyocyte-laden h-dECM bioink showing favorable cell proliferation, expansion, spreading, biomarker expressions, and synchronized contractions; whereas the volumetrically bioprinted Ms-dECM meniscus structures embedded with human mesenchymal stem cells present appropriate chondrogenic differentiation outcomes. This study supplies expanded bioink libraries for volumetric bioprinting and broadens utilities of dECM toward tissue engineering and regenerative medicine.

Multi-Material Volumetric Additive Manufacturing of Hydrogels using Gelatin as a Sacrificial Network and 3D Suspension Bath

Volumetric additive manufacturing (VAM) is an emerging layerless method for the rapid processing of reactive resins into 3D structures, where printing is much faster (seconds) than other lithography and direct ink writing methods (minutes to hours). As a vial of resin rotates in the VAM process, patterned light exposure defines a 3D object and then resin that has not undergone gelation can be washed away. Despite the promise of VAM, there are challenges with the printing of soft hydrogel materials from non-viscous precursors, including multi-material constructs. To address this, sacrificial gelatin is used to modulate resin viscosity to support the cytocompatible VAM printing of macromers based on poly(ethylene glycol) (PEG), hyaluronic acid (HA), and polyacrylamide (PA). After printing, gelatin is removed by washing at an elevated temperature. To print multi-material constructs, the gelatin-containing resin is used as a shear-yielding suspension bath (including HA to further modulate bath properties) where ink can be extruded into the bath to define a multi-material resin that can then be processed with VAM into a defined object. Multi-material constructs of methacrylated HA (MeHA) and gelatin methacrylamide (GelMA) are printed (as proof-of-concept) with encapsulated mesenchymal stromal cells (MSCs), where the local hydrogel properties guide cell spreading behavior with culture.

Approaching Standardization: Mechanical Material Testing of Macroscopic Two-Photon Polymerized Specimens

Two-photon polymerization (2PP) is becoming increasingly established as additive manufacturing technology for microfabrication due to its high-resolution and the feasibility of generating complex parts. Until now, the high resolution of 2PP is also its bottleneck, as it limited throughput and therefore restricted the application to the production of microparts. Thus, mechanical properties of 2PP materials can only be characterized using nonstandardized specialized microtesting methods. Due to recent advances in 2PP technology, it is now possible to produce parts in the size of several millimeters to even centimeters, finally permitting the fabrication of macrosized testing specimens. Besides suitable hardware systems, 2PP materials exhibiting favorable mechanical properties that allow printing of up-scaled parts are strongly demanded. In this work, the up-scalability of three different photopolymers is investigated using a high-throughput 2PP system and low numerical aperture optics. Testing specimens in the cm-range are produced and tested with common or even standardized material testing methods available in conventionally equipped polymer testing labs. Examples of the characterization of mechanical, thermo-mechanical, and fracture properties of 2PP processed materials are shown. Additionally, aspects such as postprocessing and aging are investigated. This lays a foundation for future expansion of the 2PP technology to broader industrial application.

Light from Afield: Fast, High-Resolution, and Layer-Free Deep Vat 3D Printing

Harnessing light for cross-linking of photoresponsive materials has revolutionized the field of 3D printing. A wide variety of techniques leveraging broad-spectrum light shaping have been introduced as a way to achieve fast and high-resolution printing, with applications ranging from simple prototypes to biomimetic engineered tissues for regenerative medicine. Conventional light-based printing techniques use cross-linking of material in a layer-by-layer fashion to produce complex parts. Only recently, new techniques have emerged which deploy multidirection, tomographic, light-sheet or filamented light-based image projections deep into the volume of resin-filled vat for photoinitiation and cross-linking. These Deep Vat printing (DVP) approaches alleviate the need for layer-wise printing and enable unprecedented fabrication speeds (within a few seconds) with high resolution (>10 μm). Here, we elucidate the physics and chemistry of these processes, their commonalities and differences, as well as their emerging applications in biomedical and non-biomedical fields. Importantly, we highlight their limitations, and future scope of research that will improve the scalability and applicability of these DVP techniques in a wide variety of engineering and regenerative medicine applications.

Growing three-dimensional objects with light

Vat photopolymerization (VP) additive manufacturing enables fabrication of complex 3D objects by using light to selectively cure a liquid resin. Developed in the 1980s, this technique initially had few practical applications due to limitations in print speed and final part material properties. In the four decades since the inception of VP, the field has matured substantially due to simultaneous advances in light delivery, interface design, and materials chemistry. Today, VP materials are used in a variety of practical applications and are produced at industrial scale. In this perspective, we trace the developments that enabled this printing revolution by focusing on the enabling themes of light, interfaces, and materials. We focus on these fundamentals as they relate to continuous liquid interface production (CLIP), but provide context for the broader VP field. We identify the fundamental physics of the printing process and the key breakthroughs that have enabled faster and higher-resolution printing, as well as production of better materials. We show examples of how in situ print process monitoring methods such as optical coherence tomography can drastically improve our understanding of the print process. Finally, we highlight areas of recent development such as multimaterial printing and inorganic material printing that represent the next frontiers in VP methods.

Additive Manufacturing Provides Infinite Possibilities for Self-Sensing Technology

Integrating sensors and other functional parts in one device can enable a new generation of integrated intelligent devices that can perform self-sensing and monitoring autonomously. Applications include buildings that detect and repair damage, robots that monitor conditions and perform real-time correction and reconstruction, aircraft capable of real-time perception of the internal and external environment, and medical devices and prosthetics with a realistic sense of touch. Although integrating sensors and other functional parts into self-sensing intelligent devices has become increasingly common, additive manufacturing has only been marginally explored. This review focuses on additive manufacturing integrated design, printing equipment, and printable materials and stuctures. The importance of the material, structure, and function of integrated manufacturing are highlighted. The study summarizes current challenges to be addressed and provides suggestions for future development directions.

Advances in Cell-Rich Inks for Biofabricating Living Architectures

Advancing biofabrication toward manufacturing living constructs with well-defined architectures and increasingly biologically relevant cell densities is highly desired to mimic the biofunctionality of native human tissues. The formulation of tissue-like, cell-dense inks for biofabrication remains, however, challenging at various levels of the bioprinting process. Promising advances have been made toward this goal, achieving relatively high cell densities that surpass those found in conventional platforms, pushing the current boundaries closer to achieving tissue-like cell densities. On this focus, herein the overarching challenges in the bioprocessing of cell-rich living inks into clinically grade engineered tissues are discussed, as well as the most recent advances in cell-rich living ink formulations and their processing technologies are highlighted. Additionally, an overview of the foreseen developments in the field is provided and critically discussed.

Zero-dimensional halide hybrid bulk glass exhibiting reversible photochromic ultralong phosphorescence

Dynamically responsive materials, capable of reversible changes in color appearance and/or photoemission upon external stimuli, have attracted substantial attention across various fields. This study presents an effective approach wherein switchable modulation of photochromism and ultralong phosphorescence can be achieved simultaneously in a zero-dimensional organic-inorganic halide hybrid glass doped with 4,4´-bipyridine. The facile fabrication of large-scale glasses is accomplished through a combined grinding-melting-quenching process. The persistent luminescence can be regulated through the photochromic switch induced by photo-generated radicals. Furthermore, the incorporation of the aggregation-induced chirality effect generates intriguing circularly polarized luminescence, with an optical dissymmetry factor (glum) reaching the order of 10-2. Exploiting the dynamic ultralong phosphorescence, this work further achieves promising applications, such as three-dimensional optical storage, rewritable photo-patterning, and multi-mode anti-counterfeiting with ease. Therefore, this study introduces a smart hybrid glass platform as a new photo-responsive switchable system, offering versatility for a wide array of photonic applications.

Microgels for Cell Delivery in Tissue Engineering and Regenerative Medicine

Microgels prepared from natural or synthetic hydrogel materials have aroused extensive attention as multifunctional cells or drug carriers, that are promising for tissue engineering and regenerative medicine. Microgels can also be aggregated into microporous scaffolds, promoting cell infiltration and proliferation for tissue repair. This review gives an overview of recent developments in the fabrication techniques and applications of microgels. A series of conventional and novel strategies including emulsification, microfluidic, lithography, electrospray, centrifugation, gas-shearing, three-dimensional bioprinting, etc. are discussed in depth. The characteristics and applications of microgels and microgel-based scaffolds for cell culture and delivery are elaborated with an emphasis on the advantages of these carriers in cell therapy. Additionally, we expound on the ongoing and foreseeable applications and current limitations of microgels and their aggregate in the field of biomedical engineering. Through stimulating innovative ideas, the present review paves new avenues for expanding the application of microgels in cell delivery techniques.

Rapid Fabrication of Silica Microlens Arrays via Glass 3D Printing

Rapid manufacturing of high purity fused silica glass micro-optics using a filament-based glass 3D printer has been demonstrated. A multilayer 5 × 5 microlens array was printed and subsequently characterized, showing fully dense lenses with uniform focal lengths and good imaging performance. A surface roughness on the order of Ra = 0.12 nm was achieved. Printing time for each lens was <10 s. Creating arrays with multifocal imaging capabilities was possible by individually varying the number of printed layers and radius for each lens, effectively changing the lens height and curvature. Glass 3D printing is shown in this study to be a versatile approach for fabricating silica micro-optics suitable for rapid prototyping or manufacturing.

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.

Electrochemically Responsive 3D Nanoarchitectures

Responsive nanomaterials are being developed to create new unique functionalities such as switchable colors and adhesive properties or other programmable features in response to external stimuli. While many existing examples rely on changes in temperature, humidity, or pH, this study aims to explore an alternative approach relying on simple electric input signals. More specifically, 3D electrochromic architected microstructures are developed using carbon nanotube-Tin (Sn) composites that can be reconfigured by lithiating Sn with low power electric input (≈50 nanowatts). These microstructures have a continuous, regulated, and non-volatile actuation determined by the extent of the electrochemical lithiation process. In addition, this proposed fabrication process relies only on batch lithographic techniques, enabling the parallel production of thousands of 3D microstructures. Structures with a 30-97% change in open-end area upon actuation are demonstrated and the importance of geometric factors in the response and structural integrity of 3D architected microstructures during electrochemical actuation is highlighted.

Continuous Volumetric 3D Printing: Xolography in Flow

Additive manufacturing techniques continue to improve in resolution, geometrical freedom, and production rates, expanding their application range in research and industry. Most established techniques, however, are based on layer-by-layer polymerization processes, leading to an inherent trade-off between resolution and printing speed. Volumetric 3D printing enables the polymerization of freely defined volumes allowing the fabrication of complex geometries at drastically increased production rates and high resolutions, marking the next chapter in light-based additive manufacturing. This work advances the volumetric 3D printing technique xolography to a continuous process. Dual-color photopolymerization is performed in a continuously flowing resin, inside a tailored flow cell. Supported by simulations, the flow profile in the printing area is flattened, and resin velocities at the flow cell walls are increased to minimize unwanted polymerization via laser sheet-induced curing. Various objects are printed continuously and true to shape with smooth surfaces. Parallel object printing paves the way for up-scaling the continuous production, currently reaching production rates up to 1.75 mm3  s-1 for the presented flow cell. Xolography in flow provides a new opportunity for scaling up volumetric 3D printing with the potential to resolve the trade-off between high production rates and high resolution in light-based additive manufacturing.

Simultaneous fabrication of multiple tablets within seconds using tomographic volumetric 3D printing

3D printing is driving a shift in patient care away from a generalised model and towards personalised treatments. To complement fast-paced clinical environments, 3D printing technologies must provide sufficiently high throughputs for them to be feasibly implemented. Volumetric printing is an emerging 3D printing technology that affords such speeds, being capable of producing entire objects within seconds. In this study, for the first time, rotatory volumetric printing was used to simultaneously produce two torus- or cylinder-shaped paracetamol-loaded Printlets (3D printed tablets). Six resin formulations comprising paracetamol as the model drug, poly(ethylene glycol) diacrylate (PEGDA) 575 or 700 as photoreactive monomers, water and PEG 300 as non-reactive diluents, and lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP) as the photoinitiator were investigated. Two printlets were successfully printed in 12 to 32 s and exhibited sustained drug release profiles. These results support the use of rotary volumetric printing for efficient and effective manufacturing of various personalised medicines at the same time. With the speed and precision it affords, rotatory volumetric printing has the potential to become one of the most promising alternative manufacturing technologies in the pharmaceutical industry.

Room-Temperature Molding of Complex-Shaped Transparent Fused Silica Lenses

The high hardness, brittleness, and thermal resistance impose significant challenges in the scalable manufacturing of fused silica lenses, which are widely used in numerous applications. Taking advantage of the nanocomposites by stirring silica nanopowders with photocurable resins, the newly emerged low-temperature pre-shaping technique provides a paradigm shift in fabricating transparent fused silica components. However, preparing the silica slurry and carefully evaporating the organics may significantly increase the process complexity and decrease the manufacturing efficiency for the nanocomposite-based technique. By directly pressing pure silica nanopowders against the complex-shaped metal molds in minutes, this work reports an entirely different room-temperature molding method capable of mass replication of complex-shaped silica lenses without organic additives. After sintering the replicated lenses, fully transparent fused silica lenses with spherical, arrayed, and freeform patterns are generated with nanometric surface roughness and well-reserved mold shapes, demonstrating a scalable and cost-effective route surpassing the current techniques for the manufacturing of high-quality fused silica lenses.

Advances in volumetric bioprinting

The three-dimensional (3D) bioprinting technologies are suitable for biomedical applications owing to their ability to manufacture complex and high-precision tissue constructs. However, the slow printing speed of current layer-by-layer (bio)printing modality is the major limitation in biofabrication field. To overcome this issue, volumetric bioprinting (VBP) is developed. VBP changes the layer-wise operation of conventional devices, permitting the creation of geometrically complex, centimeter-scale constructs in tens of seconds. VBP is the next step onward from sequential biofabrication methods, opening new avenues for fast additive manufacturing in the fields of tissue engineering, regenerative medicine, personalized drug testing, and soft robotics, etc. Therefore, this review introduces the printing principles and hardware designs of VBP-based techniques; then focuses on the recent advances in VBP-based (bio)inks and their biomedical applications. Lastly, the current limitations of VBP are discussed together with future direction of research.

Two-photon polymerization of silica glass diffractive micro-optics with minimal lateral shrinkage

Three-dimensional printing enables the fabrication of silica glass optics with complex structures. However, shrinkage remains a significant obstacle to high-precision 3D printing of glass optics. Here we 3D-printed Dammann gratings (DGs) with low lateral shrinkage (<4%) using a two-photon polymerization (2PP) technique. The process consists of two steps: patterning two-photon polymerizable glass slurry with a 515 nm femtosecond laser to form desired structures and debinding/sintering the structures into transparent and dense silica glass. The sintered structures exhibited distinct shrinkage rates in the lateral against longitudinal directions. As the aspect ratio of the structures increased, the lateral shrinkage decreased, while the longitudinal shrinkage increased. Specifically, the structure with an aspect ratio of approximately 60 achieved a minimal lateral shrinkage of 1.1%, the corresponding longitudinal shrinkage was 61.7%. The printed DGs with a surface roughness below 20 nm demonstrated good beam-shaping performance. The presented technique opens up possibilities for rapid prototyping of silica diffractive optical elements.

Integrated Microwell Array-Based Microfluidic Chip with a Hand-Held Smartphone-Controlled Device for Nucleic Acid Detection

In this study, we designed a highly integrated microfluidic chip for nucleic acid extraction, amplification, and detection. Magnetic beads, which are used to capture nucleic acids on the chip, are trapped in the microwell arrays in a one-well-one-bead manner after local surface modification of the inner faces of the microwells. On-chip liquid introduction, delivery, and mixing are all carried out manually with one syringe and no other equipment. A hand-held device with precise temperature control and high-quality imaging is developed, which is only 2.3 cubic decimeters in volume and 1.2 kg in weight. Via the use of the Internet for wireless communication, the experiment and data analysis after inserting the chip into the device can be conducted by a smartphone anywhere there is an Internet connection. We carried out reverse transcription loop-mediated isothermal amplification (RT-LAMP) on the chip with the hand-held device. SARS-CoV-2 pseudoviruses are extracted, reverse transcribed, amplified, and detected on the chip with the hand-held device with satisfactory results. Thus, a highly integrated, easy-to-operate, and rapid nucleic acid detection microfluidic chip with a hand-held smartphone-controlled device is proposed, and this new platform for nucleic acid detection shows great potential for mobile point-of-care testing (POCT).

Low-temperature 3D printing of transparent silica glass microstructures

Transparent silica glass is one of the most essential materials used in society and industry, owing to its exceptional optical, thermal, and chemical properties. However, glass is extremely difficult to shape, especially into complex and miniaturized structures. Recent advances in three-dimensional (3D) printing have allowed for the creation of glass structures, but these methods involve time-consuming and high-temperature processes. Here, we report a photochemistry-based strategy for making glass structures of micrometer size under mild conditions. Our technique uses a photocurable polydimethylsiloxane resin that is 3D printed into complex structures and converted to silica glass via deep ultraviolet (DUV) irradiation in an ozone environment. The unique DUV-ozone conversion process for silica microstructures is low temperature (~220°C) and fast (<5 hours). The printed silica glass is highly transparent with smooth surface, comparable to commercial fused silica glass. This work enables the creation of arbitrary structures in silica glass through photochemistry and opens opportunities in unexplored territories for glass processing techniques.

Instrumented Flexible Glass Structure: A Bragg Grating Inscribed with Femtosecond Laser Used as a Bending Sensor

Fused silica glass is a material with outstanding mechanical, thermal and optical properties. Being a brittle material, it is challenging to shape. In the last decade, the manufacturing of monolithic flexible mechanisms in fused silica has evolved with the femtosecond-laser-assisted etching process. However, instrumenting those structures is demanding. To address this obstacle, this article proposes to inscribe a Bragg Grating sensor inside a flexure and interface it with an optical fibre to record the strain using a spectrum analyser. The strain sensitivity of this Bragg Grating sensor is characterized at 1.2 pm/μϵ (1 μϵ = 1 microstrain). Among other applications, deformation sensing can be used to record a force. Its use as a micro-force sensor is estimated. The sensor resolution is limited by our recording equipment to 30 μN over a measurement range above 10 mN. This technology can offer opportunities for surgery applications or others where precision and stability in harsh environments are required.

Development and Prospective Applications of 3D Membranes as a Sensor for Monitoring and Inducing Tissue Regeneration

For decades, tissue regeneration has been a challenging issue in scientific modeling and human practices. Although many conventional therapies are already used to treat burns, muscle injuries, bone defects, and hair follicle injuries, there remains an urgent need for better healing effects in skin, bone, and other unique tissues. Recent advances in three-dimensional (3D) printing and real-time monitoring technologies have enabled the creation of tissue-like membranes and the provision of an appropriate microenvironment. Using tissue engineering methods incorporating 3D printing technologies and biomaterials for the extracellular matrix (ECM) containing scaffolds can be used to construct a precisely distributed artificial membrane. Moreover, advances in smart sensors have facilitated the development of tissue regeneration. Various smart sensors may monitor the recovery of the wound process in different aspects, and some may spontaneously give feedback to the wound sites by releasing biological factors. The combination of the detection of smart sensors and individualized membrane design in the healing process shows enormous potential for wound dressings. Here, we provide an overview of the advantages of 3D printing and conventional therapies in tissue engineering. We also shed light on different types of 3D printing technology, biomaterials, and sensors to describe effective methods for use in skin and other tissue regeneration, highlighting their strengths and limitations. Finally, we highlight the value of 3D bioengineered membranes in various fields, including the modeling of disease, organ-on-a-chip, and drug development.

4D Additive-Subtractive Manufacturing of Shape Memory Ceramics

The development of high-temperature structural materials, such as ceramics, is limited by their extremely high melting points and the difficulty in building complicated architectures. Four-dimensional (4D) printing helps enhance the geometrical flexibility of ceramics. However, ceramic 4D printing systems are limited by the separate processes for shape and material transformations, low accuracy of morphing systems, low resolution of ceramic structures, and their time-intensive nature. Here, a paradigm for a one-step shape/material transformation, high-2D/3D/4D-precision, high-efficiency, and scalable 4D additive-subtractive manufacturing of shape memory ceramics is developed. Original/reverse and global/local multimode shape memory capabilities are achieved using macroscale SiOC-based ceramic materials. The uniformly deposited Al2 O3 -rich layer on the printed SiOC-based ceramic lattice structures results in an unusually high flame ablation performance of the complex-shaped ceramics. The proposed framework is expected to broaden the applications of high-temperature structural materials in the aerospace, electronics, biomedical, and art fields.

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.

A review of materials used in tomographic volumetric additive manufacturing

Volumetric additive manufacturing is a novel fabrication method allowing rapid, freeform, layer-less 3D printing. Analogous to computer tomography (CT), the method projects dynamic light patterns into a rotating vat of photosensitive resin. These light patterns build up a three-dimensional energy dose within the photosensitive resin, solidifying the volume of the desired object within seconds. Departing from established sequential fabrication methods like stereolithography or digital light printing, volumetric additive manufacturing offers new opportunities for the materials that can be used for printing. These include viscous acrylates and elastomers, epoxies (and orthogonal epoxy-acrylate formulations with spatially controlled stiffness) formulations, tunable stiffness thiol-enes and shape memory foams, polymer derived ceramics, silica-nanocomposite based glass, and gelatin-based hydrogels for cell-laden biofabrication. Here we review these materials, highlight the challenges to adapt them to volumetric additive manufacturing, and discuss the perspectives they present.

Graphical abstract

Supplementary Information

The online version contains supplementary material available at10.1557/s43579-023-00447-x.

Transparent and Robust Superhydrophobic Structure on Silica Glass Processed with Microstereolithography Printing

Silica glass devices are widely used due to their exceptional physical and chemical properties. However, prolonged usage may result in abrasion and contamination of silica glass devices, adversely affecting the service life. One of the most effective solutions to this issue is surface modification, in which superhydrophobicity with high transmittance and mechanical robustness is highly desired. Inspired by the concept of protective armor, we proposed a novel approach for the direct integration of robust and transparent superhydrophobic structures on silica glass. In this method, microstereolithography synergistic heat treatment processes are used to create a micrometer-scale biomimetic frame on the surface of silica glass and then filled with in situ deposited nanoparticles. The superhydrophobicity of the surface can be obtained through the nanoparticles, and the biomimetic frame can protect the surface from direct contact with external objects to achieve durability. This process allows the preparation of superhydrophobic silica structures on the silica device surface at temperatures below its melting point, which prevents any damage to the devices during the heat treatment. Moreover, up to 90% transmittance does not affect the performance of silica devices. The composite structure maintains a contact angle of over 150° after multiple abrasion tests, verifying the mechanical robustness. This innovative process paves the way for forming a high mechanical robustness and excellent transmittance protective layer on silica glass devices, which expands the application field.

Spatial-Selective Volumetric 4D Printing and Single-Photon Grafting of Biomolecules within Centimeter-Scale Hydrogels via Tomographic Manufacturing

Conventional additive manufacturing and biofabrication techniques are unable to edit the chemicophysical properties of the printed object postprinting. Herein, a new approach is presented, leveraging light-based volumetric printing as a tool to spatially pattern any biomolecule of interest in custom-designed geometries even across large, centimeter-scale hydrogels. As biomaterial platform, a gelatin norbornene resin is developed with tunable mechanical properties suitable for tissue engineering applications. The resin can be volumetrically printed within seconds at high resolution (23.68 ± 10.75 μm). Thiol-ene click chemistry allows on-demand photografting of thiolated compounds postprinting, from small to large (bio)molecules (e.g., fluorescent dyes or growth factors). These molecules are covalently attached into printed structures using volumetric light projections, forming 3D geometries with high spatiotemporal control and ≈50 μm resolution. As a proof of concept, vascular endothelial growth factor is locally photografted into a bioprinted construct and demonstrated region-dependent enhanced adhesion and network formation of endothelial cells. This technology paves the way toward the precise spatiotemporal biofunctionalization and modification of the chemical composition of (bio)printed constructs to better guide cell behavior, build bioactive cue gradients. Moreover, it opens future possibilities for 4D printing to mimic the dynamic changes in morphogen presentation natively experienced in biological tissues.

3D Printing-Enabled Design and Manufacturing Strategies for Batteries: A Review

Lithium-ion batteries (LIBs) have significantly impacted the daily lives, finding broad applications in various industries such as consumer electronics, electric vehicles, medical devices, aerospace, and power tools. However, they still face issues (i.e., safety due to dendrite propagation, manufacturing cost, random porosities, and basic & planar geometries) that hinder their widespread applications as the demand for LIBs rapidly increases in all sectors due to their high energy and power density values compared to other batteries. Additive manufacturing (AM) is a promising technique for creating precise and programmable structures in energy storage devices. This review first summarizes light, filament, powder, and jetting-based 3D printing methods with the status on current trends and limitations for each AM technology. The paper also delves into 3D printing-enabled electrodes (both anodes and cathodes) and solid-state electrolytes for LIBs, emphasizing the current state-of-the-art materials, manufacturing methods, and properties/performance. Additionally, the current challenges in the AM for electrochemical energy storage (EES) applications, including limited materials, low processing precision, codesign/comanufacturing concepts for complete battery printing, machine learning (ML)/artificial intelligence (AI) for processing optimization and data analysis, environmental risks, and the potential of 4D printing in advanced battery applications, are also presented.

Deconvolution volumetric additive manufacturing

Volumetric additive manufacturing techniques are a promising pathway to ultra-rapid light-based 3D fabrication. Their widespread adoption, however, demands significant improvement in print fidelity. Currently, volumetric additive manufacturing prints suffer from systematic undercuring of fine features, making it impossible to print objects containing a wide range of feature sizes, precluding effective adoption in many applications. Here, we uncover the reason for this limitation: light dose spread in the resin due to chemical diffusion and optical blurring, which becomes significant for features ⪅0.5 mm. We develop a model that quantitatively predicts the variation of print time with feature size and demonstrate a deconvolution method to correct for this error. This enables prints previously beyond the capabilities of volumetric additive manufacturing, such as a complex gyroid structure with variable thickness and a fine-toothed gear. These results position volumetric additive manufacturing as a mature 3D printing method, all but eliminating the gap to industry-standard print fidelity.

Three-dimensional printing of silica glass with sub-micrometer resolution

Silica glass is a high-performance material used in many applications such as lenses, glassware, and fibers. However, modern additive manufacturing of micro-scale silica glass structures requires sintering of 3D-printed silica-nanoparticle-loaded composites at ~1200 °C, which causes substantial structural shrinkage and limits the choice of substrate materials. Here, 3D printing of solid silica glass with sub-micrometer resolution is demonstrated without the need of a sintering step. This is achieved by locally crosslinking hydrogen silsesquioxane to silica glass using nonlinear absorption of sub-picosecond laser pulses. The as-printed glass is optically transparent but shows a high ratio of 4-membered silicon-oxygen rings and photoluminescence. Optional annealing at 900 °C makes the glass indistinguishable from fused silica. The utility of the approach is demonstrated by 3D printing an optical microtoroid resonator, a luminescence source, and a suspended plate on an optical-fiber tip. This approach enables promising applications in fields such as photonics, medicine, and quantum-optics.

Laser-Induced Cavitation-Assisted True 3D Nano-Sculpturing of Hard Materials

Femtosecond lasers enable flexible and thermal-damage-free ablation of solid materials and are expected to play a critical role in high-precision cutting, drilling, and shaping of electronic chips, display panels, and industrial parts. Although the potential applications are theoretically predicted, true 3D nano-sculpturing of solids such as glasses and crystals, has not yet been demonstrated, owing to the technical challenge of negative cumulative effects of surface changes and debris accumulation on the delivery of laser pulses and subsequent material removal during direct-write ablation. Here, a femtosecond laser-induced cavitation-assisted true 3D nano-sculpturing technique based on the ingenious combination of cavitation dynamics and backside ablation is proposed to achieve stable clear-field point-by-point material removal in real time for precise 3D subtractive fabrication on various difficult-to-process materials. As a result, 3D devices including free-form silica lenses, micro-statue with vivid facial features, and rotatable sapphire micro-mechanical turbine, all with surface roughness less than 10 nm are readily produced. The true 3D processing capability can immediately enable novel structural and functional micro-nano optics and non-silicon micro-electro-mechanical systems based on various hard solids.

Ultra-resolution scalable microprinting

Projection micro stereolithography (PµSL) is a digital light processing (DLP) based printing technique for producing structured microparts. In this approach there is often a tradeoff between the largest object that can be printed and the minimum feature size, with higher resolution generally reducing the overall extent of the structure. The ability to produce structures with high spatial resolution and large overall volume, however, is immensely important for the creation of hierarchical materials, microfluidic devices and bioinspired constructs. In this work, we report a low-cost system with 1 µm optical resolution, representing the highest resolution system yet developed for the creation of micro-structured parts whose overall dimensions are nevertheless on the order of centimeters. To do so, we examine the limits at which PµSL can be applied at scale as a function of energy dosage, resin composition, cure depth and in-plane feature resolution. In doing so we develop a unique exposure composition approach that allows us to greatly improve the resolution of printed features. This ability to construct high-resolution scalable microstructures has the potential to accelerate advances in emerging areas, including 3D metamaterials, tissue engineering and bioinspired constructs.

Volumetric Printing of Thiol-Ene Photo-Cross-Linkable Poly(ε-caprolactone): A Tunable Material Platform Serving Biomedical Applications

Current thoroughly described biodegradable and cross-linkable polymers mainly rely on acrylate cross-linking. However, despite the swift cross-linking kinetics of acrylates, the concomitant brittleness of the resulting materials limits their applicability. Here, photo-cross-linkable poly(ε-caprolactone) networks through orthogonal thiol-ene chemistry are introduced. The step-growth polymerized networks are tunable, predictable by means of the rubber elasticity theory and it is shown that their mechanical properties are significantly improved over their acrylate cross-linked counterparts. Tunability is introduced to the materials, by altering M_c (or the molar mass between cross-links), and its effect on the thermal properties, mechanical strength and degradability of the materials is evaluated. Moreover, excellent volumetric printability is illustrated and the smallest features obtained via volumetric 3D-printing to date are reported, for thiol-ene systems. Finally, by means of in vitro and in vivo characterization of 3D-printed constructs, it is illustrated that the volumetrically 3D-printed materials are biocompatible. This combination of mechanical stability, tunability, biocompatibility, and rapid fabrication by volumetric 3D-printing charts a new path toward bedside manufacturing of biodegradable patient-specific implants.