Additive Manufacturing: Applications and Directions in Photonics and Optoelectronics

Recent Advances in 4D Printing of Advanced Materials and Structures for Functional Applications

4D printing has attracted tremendous worldwide attention during the past decade. This technology enables the shape, property, or functionality of printed structures to change with time in response to diverse external stimuli, making the original static structures alive. The revolutionary 4D-printing technology offers remarkable benefits in controlling geometric and functional reconfiguration, thereby showcasing immense potential across diverse fields, including biomedical engineering, electronics, robotics, and photonics. Here, a comprehensive review of the latest achievements in 4D printing using various types of materials and different additive manufacturing techniques is presented. The state-of-the-art strategies implemented in harnessing various 4D-printed structures are highlighted, which involve materials design, stimuli, functionalities, and applications. The machine learning approach explored for 4D printing is also discussed. Finally, the perspectives on the current challenges and future trends toward further development in 4D printing are summarized.

Vat Photopolymerization 3D Printing in Dentistry: A Comprehensive Review of Actual Popular Technologies

In this comprehensive review, the current state of the art and recent advances in 3D printing in dentistry are explored. This article provides an overview of the fundamental principles of 3D printing with a focus on vat photopolymerization (VP), the most commonly used technological principle in dental practice, which includes SLA, DLP, and LCD (or mSLA) technologies. The advantages, disadvantages, and shortcomings of these technologies are also discussed. This article delves into the key stages of the dental 3D printing process, from computer-aided design (CAD) to postprocessing, emphasizing the importance of postrinsing and postcuring to ensure the biocompatibility of custom-made medical devices. Legal considerations and regulatory obligations related to the production of custom medical devices through 3D printing are also addressed. This article serves as a valuable resource for dental practitioners, researchers, and health care professionals interested in applying this innovative technology in clinical practice.

Manufacturing 3D Biomimetic Tissue: A Strategy Involving the Integration of Electrospun Nanofibers with a 3D-Printed Framework for Enhanced Tissue Regeneration

3D printing and electrospinning are versatile techniques employed to produce 3D structures, such as scaffolds and ultrathin fibers, facilitating the creation of a cellular microenvironment in vitro. These two approaches operate on distinct working principles and utilize different polymeric materials to generate the desired structure. This review provides an extensive overview of these techniques and their potential roles in biomedical applications. Despite their potential role in fabricating complex structures, each technique has its own limitations. Electrospun fibers may have ambiguous geometry, while 3D-printed constructs may exhibit poor resolution with limited mechanical complexity. Consequently, the integration of electrospinning and 3D-printing methods may be explored to maximize the benefits and overcome the individual limitations of these techniques. This review highlights recent advancements in combined techniques for generating structures with controlled porosities on the micro-nano scale, leading to improved mechanical structural integrity. Collectively, these techniques also allow the fabrication of nature-inspired structures, contributing to a paradigm shift in research and technology. Finally, the review concludes by examining the advantages, disadvantages, and future outlooks of existing technologies in addressing challenges and exploring potential opportunities.

Design of sustainable 3D printable polylactic acid composites with high lignin content

In this study, we report the development of a sustainable polymer system with 50 wt% lignin content, suitable for additive manufacturing and high value-added utilization of lignin. The plasticized polylactic acid (PLA) was incorporated with lignin to develop the bendable and malleable green composites with excellent 3D printing adaptability. The biocomposites exhibit increases of 765.54 % and 125.27 % in both elongation and toughness, respectively. The plasticizer enhances the dispersion of lignin and the molecular mobility of the PLA chains. The good dispersion of lignin particles within the structure and the reduction of chemical cross-linking promote the local relaxation of the polymer chains. The good local relaxation of the polymer chains and the high flexibility allow to obtain a better integration between the printed layers with good printability. This research demonstrates the promising potential of this composite system for sustainable manufacturing and provides insights into novel material design for high-value applications of lignin.

Experimental characterization of Spherical Bragg Resonators for electromagnetic emission engineering at microwave frequencies

This work reports experimental investigation and numerical validation of millimeter-sized Spherical Bragg Resonators (SBRs) fabricated using 3D printing technology. The frequency dependencies of the reflection and transmission coefficients were analyzed, and eigenfrequency values were calculated to examine the density of photonic states in air/PLA-polylactide SBRs, showing the appearance of an eigenmode and an increase in the local density of states in the core of a defect cavity. A decay rate enhancement of [Formula: see text] was obtained for a dipole placed in the core of the defect SBR. The study also investigated the influence of the source position on the resonator's electromagnetic wave energy. Scattering efficiencies up to order twelve of the multipole electric and magnetic contribution in a 10-layer SBR were calculated to validate the presence of the resonant modes observed in the scattering measurements performed for parallel and perpendicular polarizations. The results demonstrate that SBRs can act as omnidirectional cavities to enhance or inhibit spontaneous emission processes by modifying the density of electromagnetic states compared to free space. This finding highlights the potential of SBRs engineering spontaneous electromagnetic emission processes in various applications, including dielectric nanoantennas, optoelectronics devices, and quantum information across the entire electromagnetic spectrum.

Trackable and highly fluorescent nanocellulose-based printable bio-resins for image-guided tissue regeneration

Dynamic tracking of cell migration during tissue regeneration remains challenging owing to imaging techniques that require sophisticated devices, are often lethal to healthy tissues. Herein, we developed a 3D printable non-invasive polymeric hydrogel based on 2,2,6,6-(tetramethylpiperidin-1-yl) oxyl (TEMPO)-oxidized nanocellulose (T-CNCs) and carbon dots (CDs) for the dynamic tracking of cells. The as-prepared T-CNC@CDs were used to fabricate a liquid bio-resin containing gelatin methacryloyl (GelMA) and polyethylene glycol diacrylate (GPCD) for digital light processing (DLP) bioprinting. The shear-thinning properties of the GPCD bio-resin were further improved by the addition of T-CNC@CDs, allowing high-resolution 3D printing and bioprinting of human cells with higher cytocompatibility (viability ∼95 %). The elastic modulus of the printed GPCD hydrogel was found to be ∼13 ± 4.2 kPa, which is ideal for soft tissue engineering. The as-fabricated hydrogel scaffold exhibited tunable structural color property owing to the addition of T-CNC@CDs. Owing to the unique fluorescent property of T-CNC@CDs, the human skin cells could be tracked within the GPCD hydrogel up to 30 days post-printing. Therefore, we anticipate that GPCD bio-resin can be used for 3D bioprinting with high structural stability, dynamic tractability, and tunable mechanical stiffness for image-guided tissue regeneration.

An Ultraviolet-Lithography-Assisted Sintering Method for Glass Microlens Array Fabrication

Glass microlens arrays (MLAs) have tremendous prospects in the fields of optical communication, sensing and high-sensitivity imaging for their excellent optical properties, high mechanical robustness and physicochemical stability. So far, glass MLAs are primarily fabricated using femtosecond laser modification assisted etching, in which the preparation procedure is time-consuming, with each concave-shaped microlens being processed using a femtosecond laser point by point. In this paper, a new method is proposed for implementing large-scale glass MLAs using glass particle sintering with the assistance of ultraviolet (UV) lithography. The glass particles are dispersed into the photoresist at first, and then immobilized as large-scaled micropillar arrays on quartz glass substrate using UV lithographing. Subsequently, the solidified photoresist is debinded and the glass particles are melted by means of sintering. By controlling the sintering conditions, the convex microlens will be self-assembled, attributed to the surface tension of the molten glass particles. Finally, MLAs with different focal lengths (0.12 to 0.2 mm) are successfully fabricated by utilizing different lithography masks. Meanwhile, we also present the optimization of the sintering parameter for eliminating the bubbles in the microlenses. The main factors that affect the focal length of the microlens and the image performance of the MLAs have been studied in detail.

Near index matching enables solid diffractive optical element fabrication via additive manufacturing

Diffractive optical elements (DOEs) have a wide range of applications in optics and photonics, thanks to their capability to perform complex wavefront shaping in a compact form. However, widespread applicability of DOEs is still limited, because existing fabrication methods are cumbersome and expensive. Here, we present a simple and cost-effective fabrication approach for solid, high-performance DOEs. The method is based on conjugating two nearly refractive index-matched solidifiable transparent materials. The index matching allows for extreme scaling up of the elements in the axial dimension, which enables simple fabrication of a template using commercially available 3D printing at tens-of-micrometer resolution. We demonstrated the approach by fabricating and using DOEs serving as microlens arrays, vortex plates, including for highly sensitive applications such as vector beam generation and super-resolution microscopy using MINSTED, and phase-masks for three-dimensional single-molecule localization microscopy. Beyond the advantage of making DOEs widely accessible by drastically simplifying their production, the method also overcomes difficulties faced by existing methods in fabricating highly complex elements, such as high-order vortex plates, and spectrum-encoding phase masks for microscopy.

Multiscale Anisotropic Scaffold Integrating 3D Printing and Electrospinning Techniques as a Heart-on-a-Chip Platform for Evaluating Drug-Induced Cardiotoxicity

Cardiac safety assessments are significant in drug discovery, as drug-induced cardiotoxicity (DIC) is the primary cause of drug attrition. Despite heart-on-a-chip (HoC) technology becoming an increasingly popular tool for evaluating DIC, its development remains a challenge owing to the anisotropic cardiac structure of the native myocardium. Herein, an anisotropic multiscale cardiac scaffold is presented via a hybrid biofabrication method by combining 3D printing with electrospinning technology, where the 3D-printed micrometer-scale scaffold frames enable mimicking the interwoven myocardium anatomical structure and the branched-aligned electrospun nanofibers network is able to directionally guide cellular arrangements. The in vitro 3D bioengineered cardiac tissues are then fabricated by encapsulating three-layer multiscale scaffolds within a photocurable methacrylated gelatin hydrogel shell. It is demonstrated that such an anisotropic multiscale structure could contribute to enhancing cardiomyocyte maturation and synchronous beating behavior. More attractively, with the integration of 3D bioengineered cardiac tissues and a self-designed microfluidic perfusion system, a 3D anisotropic HoC platform is established for evaluating DIC and cardioprotective efficacy. Collectively, these results indicate that the HoC model developed by integrating the 3D bioengineered cardiac tissues could effectively recapitulate the clinical manifestations, thereby highlighting their efficacy as a valuable preclinical platform for testing drug efficacy and cardiotoxicity.

Recent Progress in Printed Photonic Devices: A Brief Review of Materials, Devices, and Applications

Printing electronics incorporates several significant technologies, such as semiconductor devices produced by various printing techniques on flexible substrates. With the growing interest in printed electronic devices, new technologies have been developed to make novel devices with inexpensive and large-area printing techniques. This review article focuses on the most recent developments in printed photonic devices. Photonics and optoelectronic systems may now be built utilizing materials with specific optical properties and 3D designs achieved through additive printing. Optical and architected materials that can be printed in their entirety are among the most promising future research topics, as are platforms for multi-material processing and printing technologies that can print enormous volumes at a high resolution while also maintaining a high throughput. Significant advances in innovative printable materials create new opportunities for functional devices to act efficiently, such as wearable sensors, integrated optoelectronics, and consumer electronics. This article provides an overview of printable materials, printing methods, and the uses of printed electronic devices.

Highly sensitive ultrasound detection using nanofabricated polymer micro-ring resonators

Photoacoustic (PA) imaging enables noninvasive volumetric imaging of biological tissues by capturing the endogenous optical absorption contrast. Conventional ultrasound detectors using piezoelectric materials have been widely used for transducing ultrasound signals into the electrical signals for PA imaging reconstruction. However, their inherent limitations in detection bandwidth and sensitivity per unit area have unfortunately constrained the performance of PA imaging. Optical based ultrasound detection methods emerge to offer very promising solutions. In particular, polymer micro-ring resonators (MRRs) in the form of integrated photonic circuits (IPC) enable significant reduction for the sensing area to 80 μm in diameter, while maintaining highly sensitive ultrasound detection with noise equivalent pressure (NEP) of 0.49 Pa and a broad detection frequency range up to 250 MHz. The continued engineering innovation has further transformed MRRs to be transparent to the light and thus, opens up a wide range of applications, including multi-modality optical microscope with isometric resolution, PA endoscope, photoacoustic computed tomography (PACT), and more. This review article summarizes and discusses the evolution of polymer MRR design and the associated nanofabrication process for improving the performance of ultrasound detection. The resulting novel imaging applications will also be reviewed and discussed.

Interfacial Photopolymerization: A Method for Light-Based Printing of Thermoplastics

Ultraviolet (UV) printing of photopolymers is a widely adopted manufacturing method because of its high resolution and throughput. However, available printable photopolymers are typically thermosets, resulting in challenges in postprocessing and recycling of printed structures. Here, we present a new process called interfacial photopolymerization (IPP) which enables photopolymerization printing of linear chain polymers. In IPP, a polymer film is formed at the interface between two immiscible liquids, one containing a chain-growth monomer and the other containing a photoinitiator. We demonstrate the integration of IPP in a proof-of-concept projection system for printing of polyacrylonitrile (PAN) films and rudimentary multi-layer shapes . IPP shows in-plane and out-of-plane resolutions comparable to conventional photoprinting methods. Cohesive PAN films with number-average molecular weights greater than 15 kg mol^-1 are obtained, and to our knowledge this is the first report of photopolymerization printing of PAN. A macrokinetics model of IPP is developed to elucidate the transport and reaction rates involved and evaluate how reaction parameters affect film thickness and print speed. Last, demonstration of IPP in a multilayer scheme suggests its suitabiliy for three-dimensional printing of linear-chain polymers.

Mechanical strength predictability of full factorial, Taguchi, and Box Behnken designs: Optimization of thermal settings and Cellulose Nanofibers content in PA12 for MEX AM

Optimization of reinforced nanocomposites for MEX 3D-printing remain strong industrial claims. Herein, the efficacy of three modeling methods, i.e., full factorial (FFD), Taguchi (TD), and Box-Behnken (BBD), on the performance of MEX 3D printed nanocomposites was investigated, aiming to reduce the experimental effort. Filaments of medical-grade Polyamide 12 (PA12) reinforced with Cellulose NanoFibers (CNF) were evolved. Besides the CNF loading, 3D printing settings such as Nozzle (NT) and Bed (BΤ) Temperatures were optimization goals aiming to maximize the mechanical response. Three parameters and three levels of FFD were compliant with the ASTM-D638 standard (27 runs, five repetitions). An L9 orthogonal TD and a 15 runs BBD were compiled. In FFD, wt.3%CNF, 270 °C NT, and 80 °C BΤ led to 24% higher tensile strength compared to pure PA12. TGA, RAMAN, and SEM analyses interpreted the reinforcement mechanisms. TD and BBD exhibited fair approximations, requiring 7.4% and 11.8% of the FFD experimental effort.

3D bioprinting and its innovative approach for biomedical applications

3D bioprinting or additive manufacturing is an emerging innovative technology revolutionizing the field of biomedical applications by combining engineering, manufacturing, art, education, and medicine. This process involved incorporating the cells with biocompatible materials to design the required tissue or organ model in situ for various in vivo applications. Conventional 3D printing is involved in constructing the model without incorporating any living components, thereby limiting its use in several recent biological applications. However, this uses additional biological complexities, including material choice, cell types, and their growth and differentiation factors. This state-of-the-art technology consciously summarizes different methods used in bioprinting and their importance and setbacks. It also elaborates on the concept of bioinks and their utility. Biomedical applications such as cancer therapy, tissue engineering, bone regeneration, and wound healing involving 3D printing have gained much attention in recent years. This article aims to provide a comprehensive review of all the aspects associated with 3D bioprinting, from material selection, technology, and fabrication to applications in the biomedical fields. Attempts have been made to highlight each element in detail, along with the associated available reports from recent literature. This review focuses on providing a single platform for cancer and tissue engineering applications associated with 3D bioprinting in the biomedical field.

Non-specular reflection of a narrow spatially phase-modulated Gaussian beam

The lateral and angular Goos-Hänchen shifts undergone upon reflection on a dielectric plate by a spatially phase-modulated Gaussian beam are derived. It is shown that the amplitude and direction of both lateral and angular shifts are very sensitive to the degree of spatial phase modulation of the incident beam, so that such modulation thus provides a means to control those shifts. It is also shown that the modulation incurs some beam reshaping upon reflection. Analytical calculations of the lateral shift are found to be in good agreement with numerical simulations of beam propagation before and after reflection. In these simulations, the required spatial transverse phase modulation is achieved by focusing a microwave Gaussian beam onto the dielectric plate with a non-spherical lens or a flat-surfaced thin lamella exhibiting a suitable gradient of its refractive index. The optimal parameters governing the spatial phase modulation are discussed to achieve: (i) enhancement of the lateral shift of a spatially phase-modulated beam in comparison to that of a non-modulated beam and (ii) simultaneous large values of reflectivity and of the lateral shift, while keeping the reshaping of the reflected beam to a minimum.

Thermal feature-size enhancement in multiphoton photoresists

We demonstrate a new approach for decreasing the feature size in multiphoton absorption polymerization (MAP). Acrylic photoresists containing the photoinitiator KL68 (bis-[4-(diphenylamino) stryl]-1-(2-ethylhexyloxy), 4-(methoxy)benzene) exhibit a proportional velocity (PROVE) dependence, yielding smaller feature sizes at lower fabrication speeds. The feature size in this photoresist decreases substantially with a temperature increase of less than 10°C when all other fabrication parameters are kept constant, suggesting that the PROVE behavior results from local heating. Although higher temperatures have previously been associated with decreased feature sizes in MAP, the effect observed here is considerably stronger than in previous work, and is shown to be a property of the photoinitiator. This discovery opens the door to exploiting thermal gradients to improve resolution in MAP lithography.

Optical Strain Gauge Prototype Based on a High Sensitivity Balloon-like Interferometer and Additive Manufacturing

An optical strain gauge based on a balloon-like interferometer structure formed by a bent standard single-mode fiber combined with a 3D printer piece has been presented and demonstrated, which can be used to measure displacement. The interferometer has a simple and compact size, easy fabrication, low cost, and is repeatable. The sensor is based on the interference between the core and cladding modes. This is caused by the fiber's curvature because when light propagates through the curved balloon-shaped interferometer region, a portion of it will be released from the core limitation and coupled to the cladding. The balloon has an axial displacement as a result of how the artwork was constructed. The sensor head is sandwiched between two cantilevers such that when there is a displacement, the dimension associated with the micro bend is altered. The sensor response as a function of displacement can be determined using wavelength shift or intensity change interrogation techniques. Therefore, this optical strain gauge is a good option for applications where structure displacement needs to be examined. The sensor presents a sensitivity of 55.014 nm for displacement measurements ranging from 0 to 10 mm and a strain sensitivity of 500.13 pm/μϵ.

Sequential process optimization for a digital light processing system to minimize trial and error

In additive manufacturing, logical and efficient workflow optimization enables successful production and reduces cost and time. These attempts are essential for preventing fabrication problems from various causes. However, quantitative analysis and integrated management studies of fabrication issues using a digital light processing (DLP) system are insufficient. Therefore, an efficient optimization method is required to apply several materials and extend the application of the DLP system. This study proposes a sequential process optimization (SPO) to manage the initial adhesion, recoating, and exposure energy. The photopolymerization characteristics and viscosity of the photocurable resin were quantitatively analyzed through process conditions such as build plate speed, layer thickness, and exposure time. The ability of the proposed SPO was confirmed by fabricating an evaluation model using a biocompatible resin. Furthermore, the biocompatibility of the developed resin was verified through experiments. The existing DLP process requires several trials and errors in process optimization. Therefore, the fabrication results are different depending on the operator’s know-how. The use of the proposed SPO enables a systematic approach for optimizing the process conditions of a DLP system. As a result, the DLP system is expected to be more utilized.

Two-Photon Laser Microprinting of Highly Ordered Nanoporous Materials Based on Hexagonal Columnar Liquid Crystals

Nanoporous materials relying on supramolecular liquid crystals (LCs) are excellent candidates for size- and charge-selective membranes. However, whether they can be manufactured using printing technologies remained unexplored so far. In this work, we develop a new approach for the fabrication of ordered nanoporous microstructures based on supramolecular LCs using two-photon laser printing. In particular, we employ photo-cross-linkable hydrogen-bonded complexes, that self-assemble into columnar hexagonal (Colh) mesophases, as the base of our printable photoresist. The presence of photopolymerizable groups in the periphery of the molecules enables the printability using a laser. We demonstrate the conservation of the Colh arrangement and of the adsorptive properties of the materials after laser microprinting, which highlights the potential of the approach for the fabrication of functional nanoporous structures with a defined geometry. This first example of printable Colh LC should open new opportunities for the fabrication of functional porous microdevices with potential application in catalysis, filtration, separation, or molecular recognition.

A Simple Optical Sensor Based on Multimodal Interference Superimposed on Additive Manufacturing for Diameter Measurement

In many areas, the analysis of a cylindrical structure is necessary, and a form to analyze it is by evaluating the diameter changes. Some areas can be cited: pipelines for oil or gas distribution and radial growth of trees whose diameter changes are directly related to irrigation and the radial expansion since it depends on the water soil deficit. For some species, these radial variations can change in around 5 mm. This paper proposes and experimentally investigates a sensor based on a core diameter mismatch technique for diameter changes measurement. The sensor structure is a combination of a cylindrical piece developed using a 3D printer and a Mach-Zehnder interferometer. The pieces were developed to assist in monitoring the diameter variation. It is formed by splicing an uncoated short section of MMF (Multimode Fiber) between two standard SMFs (Singlemode Fibers) called SMF-MMF-SMF (SMS), where the MMF length is 15 mm. The work is divided into two main parts. Firstly, the sensor was fixed at two points on the first developed piece, and the diameter reduction caused dips or peaks shift of the transmittance spectrum due to curvature and strain influence. The fixation point (FP) distances used are: 5 mm, 10 mm, and 15 mm. Finally, the setup with the best sensitivity was chosen, from first results, to develop another test with an optimization. This optimization is performed in the printed piece where two supports are created so that only the strain influences the sensor. The results showed good sensitivity, reasonable dynamic range, and easy setup reproduction. Therefore, the sensor could be used for diameter variation measurement for proposed applications.

Free-standing plasmonic nanoarrays for leaky optical waveguiding and sensing

Flat optics nanogratings supported on thin free-standing membranes offer the opportunity to combine narrowband waveguided modes and Rayleigh anomalies for sensitive and tunable biosensing. At the surface of high-refractive index Si₃N₄ membranes we engineered lithographic nanogratings based on plasmonic nanostripes, demonstrating the excitation of sharp waveguided modes and lattice resonances. We achieved fine tuning of these optical modes over a broadband Visible and Near-Infrared spectrum, in full agreement with numerical calculations. This possibility allowed us to select sharp waveguided modes supporting strong near-field amplification, extending for hundreds of nanometres out of the grating and enabling versatile biosensing applications. We demonstrate the potential of this flat-optics platform by devising a proof-of-concept nanofluidic refractive index sensor exploiting the long-range waveguided mode operating at the sub-picoliter scale. This free-standing device configuration, that could be further engineered at the nanoscale, highlights the strong potential of flat-optics nanoarrays in optofluidics and nanofluidic biosensing.

Thermally Activated Delayed Fluorescent Gain Materials: Harvesting Triplet Excitons for Lasing

Thermally activated delayed fluorescent (TADF) materials have attracted increasing attention because of their ability to harvest triplet excitons via a reverse intersystem crossing process. TADF gain materials that can recycle triplet excitons for stimulated emission are considered for solving the triplet accumulation problem in electrically pumped organic solid-state lasers (OSSLs). In this mini review, recent progress in TADF gain materials is summarized, and design principles are extracted from existing reports. The construction methods of resonators based on TADF gain materials are also introduced, and the challenges and perspectives for the future development of TADF gain materials are presented. It is hoped that this review will aid the advances in TADF gain materials and thus promote the development of electrically pumped OSSLs.

Colloidal oxide nanoparticle inks for micrometer-resolution additive manufacturing of three-dimensional gas sensors

Micrometer-resolution 3D printing of functional oxides is of growing importance for the fabrication of micro-electromechanical systems (MEMSs) with customized 3D geometries. Compared to conventional microfabrication methods, additive manufacturing presents new opportunities for the low-cost, energy-saving, high-precision, and rapid manufacturing of electronics with complex 3D architectures. Despite these promises, methods for printable oxide inks are often hampered by challenges in achieving the printing resolution required by today's MEMS electronics and integration capabilities with various other electronic components. Here, a novel, facile ink design strategy is presented to overcome these challenges. Specifically, we first prepare a high-solid loading (∼78 wt%) colloidal suspension that contains polyethyleneimine (PEI)-coated stannic dioxide (SnO₂) nanoparticles, followed by PEI desorption that is induced by nitric acid (HNO₃) titration to optimize the rheological properties of the printable inks. Our achieved ∼3-5 μm printing resolution is at least an order of magnitude higher than those of other printed oxide studies employing nanoparticle ink-based printing methods demonstrated previously. Finally, various SnO₂ structures were directly printed on a MEMS-based microelectrode for acetylene detection application. The gas sensitivity measurements reveal that the device performance is strongly dependent on the printed SnO₂ structures. Specifically, the 3D structured SnO₂ gas sensor exhibits the highest response of ∼ 29.9 to 100 ppm acetylene with the fastest total response time of ∼ 65.8 s. This work presents a general ink formulation and printing strategy for functional oxides, which further provides a pathway for the additive manufacturing of oxide-based MEMSs.

New BODIPY Dyes Based on Benzoxazole as Photosensitizers in Radical Polymerization of Acrylate Monomers

A series of 2-phenacylbenzoxazole difluoroboranes named BODIPY dyes (1-8) was designed and applied as photosensitizers (PS) for radical photopolymerization of acrylate monomer. The light absorption within the ultraviolet-visible (UV-Vis) range (λ_max = 350-410 nm; ε_max = 23,000-42,500 M^-1cm^-1), that is strongly influenced by the substituents on the C3 and C4 atoms of phenyl ring, matched the emission of the Omnicure S2000 light within 320-500 nm. The photosensitizer possess fluorescence quantum yield from about 0.005 to 0.99. The 2-phenacylbenzoxazole difluoroboranes, together with borate salt (Bor), iodonium salt (Iod) or pyridinium salt (Pyr) acting as co-initiators, can generate active radicals upon the irradiation with a High Pressure Mercury Lamp which initiates a high-performance UV-Vis light-induced radical polymerization at 320-500 nm. The polymers obtained are characterized by strong photoluminescence. It was found that the type of radical generator (co-initiator) has a significant effect on the kinetic of radical polymerization of acrylate monomer. Moreover, the chemical structure of the BODIPY dyes does not influence the photoinitiating ability of the photoinitiator. The concentration of the photoinitiating system affects the photoinitiating performance. These 2-phenacylbenzoxazole difluoroborane-based photoinitiating systems have promising applications in UV-Vis-light induced polymerization.

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 .

Dispersion Mapping in 3-Dimensional Core-Shell Photonic Crystal Lattices Capable of Negative Refraction in the Mid-Infrared

Engineering of the dispersion properties of a photonic crystal (PhC) opens a new paradigm for the design and function of PhC devices. Exploiting the dispersion properties of PhCs allows control over wave propagation within a PhC. We describe the design, fabrication, and experimental observation of photonic bands for 3D PhCs capable of negative refraction in the mid-infrared. Band structure and equifrequency contours were calculated to inform the design of 3D polymer-germanium core-shell PhCs, which were fabricated using two-photon lithography direct laser writing and sputtering. We successfully characterized a polymer-Ge core-shell lattice and mapped its band structure, which we then used to calculate the PhC refraction behavior. An analysis of wave propagation revealed that this 3D core-shell PhC refracts light negatively and possesses an effective negative index of refraction in the experimentally observed region. These results suggest that architected nanolattices have the potential to serve as new optical components and devices across infrared frequencies.

3D-printed silica with nanoscale resolution

Fabricating inorganic materials with designed three-dimensional nanostructures is an exciting yet challenging area of research and industrial application. Here, we develop an approach to 3D print high-quality nanostructures of silica with sub-200 nm resolution and with the flexible capability of rare-earth element doping. The printed SiO₂ can be either amorphous glass or polycrystalline cristobalite controlled by the sintering process. The 3D-printed nanostructures demonstrate attractive optical properties. For instance, the fabricated micro-toroid optical resonators can reach quality factors (Q) of over 10⁴. Moreover, and importantly for optical applications, doping and codoping of rare-earth salts such as Er³⁺, Tm³⁺, Yb³⁺, Eu³⁺ and Nd³⁺ can be directly implemented in the printed SiO₂ structures, showing strong photoluminescence at the desired wavelengths. This technique shows the potential for building integrated microphotonics with silica via 3D printing.

Printable Smart Materials and Devices: Strategies and Applications

Smart materials are a kind of functional materials which can sense and response to environmental conditions or stimuli from optical, electrical, magnetic mechanical, thermal, and chemical signals, etc. Patterning of smart materials is the key to achieving large-scale arrays of functional devices. Over the last decades, printing methods including inkjet printing, template-assisted printing, and 3D printing are extensively investigated and utilized in fabricating intelligent micro/nano devices, as printing strategies allow for constructing multidimensional and multimaterial architectures. Great strides in printable smart materials are opening new possibilities for functional devices to better serve human beings, such as wearable sensors, integrated optoelectronics, artificial neurons, and so on. However, there are still many challenges and drawbacks that need to be overcome in order to achieve the controllable modulation between smart materials and device performance. In this review, we give an overview on printable smart materials, printing strategies, and applications of printed functional devices. In addition, the advantages in actual practices of printing smart materials-based devices are discussed, and the current limitations and future opportunities are proposed. This review aims to summarize the recent progress and provide reference for novel smart materials and printing strategies as well as applications of intelligent devices.

Assembly of multicomponent structures from hundreds of micron-scale building blocks using optical tweezers

The fabrication of three-dimensional (3D) microscale structures is critical for many applications, including strong and lightweight material development, medical device fabrication, microrobotics, and photonic applications. While 3D microfabrication has seen progress over the past decades, complex multicomponent integration with small or hierarchical feature sizes is still a challenge. In this study, an optical positioning and linking (OPAL) platform based on optical tweezers is used to precisely fabricate 3D microstructures from two types of micron-scale building blocks linked by biochemical interactions. A computer-controlled interface with rapid on-the-fly automated recalibration routines maintains accuracy even after placing many building blocks. OPAL achieves a 60-nm positional accuracy by optimizing the molecular functionalization and laser power. A two-component structure consisting of 448 1-µm building blocks is assembled, representing the largest number of building blocks used to date in 3D optical tweezer microassembly. Although optical tweezers have previously been used for microfabrication, those results were generally restricted to single-material structures composed of a relatively small number of larger-sized building blocks, with little discussion of critical process parameters. It is anticipated that OPAL will enable the assembly, augmentation, and repair of microstructures composed of specialty micro/nanomaterial building blocks to be used in new photonic, microfluidic, and biomedical devices.

Material-structure-performance integrated laser-metal additive manufacturing

Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with innovative structures and multimaterial layouts to meet the increasing demand from industries such as aviation, aerospace, automobile manufacturing, and energy production. We highlight two methodological ideas for MSPI-AM-"the right materials printed in the right positions" and "unique structures printed for unique functions"-to realize major improvements in performance and function. We establish how cross-scale mechanisms to coordinate nano/microscale material development, mesoscale process monitoring, and macroscale structure and performance control can be used proactively to achieve high performance with multifunctionality. MSPI-AM exemplifies the revolution of design and manufacturing strategies for AM and its technological enhancement and sustainable development.

3D Printing of Transparent Spinel Ceramics with Transmittance Approaching the Theoretical Limit

3D printing of transparent ceramics has attracted great attention recently but faces the challenges of low transparency and low printing resolution. Herein, magnesium aluminate spinel transparent ceramics with transmittance reaching 97% of the theoretical limit are successfully fabricated using a stereolithography-based 3D printing method assisted by hot isostatic pressing and the critical factors governing the transparency are revealed. Various transparent spinel lenses and microlattices are printed at a high resolution of ≈100-200 µm. The 3D printed spinel lens demonstrates fairly good optical imaging ability, and the printed spinel diamond microlattices as a transparent photocatalyst support for TiO₂ significantly enhance its photocatalytic efficiency compared with its opaque counterparts. Compared with other 3D printed transparent materials such as silica glass or organic polymers, the printed spinel ceramics have the advantages of broad optical window, high hardness, excellent high-temperature stability, and chemical resistance and therefore, have great potential to be used in various optical lenses/windows and photocatalyst supports for application in harsh environments.

Two-Photon Polymerization of Nanocomposites for the Fabrication of Transparent Fused Silica Glass Microstructures

Fused silica glass is the material of choice for many high-performance components in optics due to its high optical transparency combined with its high thermal, chemical, and mechanical stability. Especially, the generation of fused silica microstructures is of high interest for microoptical and biomedical applications. Direct laser writing (DLW) is a suitable technique for generating such devices, as it enables nearly arbitrary structuring down to the sub-micrometer level. In this work, true 3D structuring of transparent fused silica glass using DLW with tens of micrometer resolution and a surface roughness of R_a  ≈ 6 nm is demonstrated. The process uses a two-photon curable silica nanocomposite resin that can be structured by DLW, with the printout being convertible to transparent fused silica glass via thermal debinding and sintering. This technology will enable a plethora of applications from next-generation optics and photonics to microfluidic and biomedical applications with resolutions on the scale of tens of micrometers.

3D-Printed Quantum Dot Nanopixels

The pixel is the minimum unit used to represent or record information in photonic devices. The size of the pixel determines the density of the integrated information, such as the resolution of displays or cameras. Most methods used to produce display pixels are based on two-dimensional patterning of light-emitting materials. However, the brightness of the pixels is limited when they are miniaturized to nanoscale dimensions owing to their limited volume. Herein, we demonstrate the production of three-dimensional (3D) pixels with nanoscale dimensions based on the 3D printing of quantum dots embedded in polymer nanowires. In particular, a femtoliter meniscus was used to guide the solidification of liquid inks to form vertically freestanding nanopillar structures. Based on the 3D layout, we show high-density integration of color pixels, with a lateral dimension of 620 nm and a pitch of 3 μm for each of the red, green, and blue colors. The 3D structure enabled a 2-fold increase in brightness without significant effects on the spatial resolution of the pixels. In addition, we demonstrate individual control of the brightness based on a simple adjustment of the height of the 3D pixels. This method can be used to achieve super-high-resolution display devices and various photonic applications across a range of disciplines.

Characterization of novel 3D printed plastic scintillation dosimeters

We propose a new methodology for the fabrication and evaluation of scintillating detector elements using a consumer grade fusion deposition modeling (FDM) 3D printer. In this study we performed a comprehensive investigation into both the effects of the 3D printing process on the scintillation light output of 3D printed plastic scintillation dosimeters (PSDs) and their associated dosimetric properties. Fabrication properties including print variability, layer thickness, anisotropy and extrusion temperature were assessed for 1 cm³ printed samples. We then examined the stability, dose linearity, dose rate proportionality, energy dependence and reproducibility of the 3D printed PSDs compared to benchmarks set by commercially available products. Experimental results indicate that the shape of the emission spectrum of the 3D printed PSDs do not show significant spectral differences when compared to the emission spectrum of the commercial sample. However, the magnitude of scintillation light output was found to be strongly dependent on the parameters of the fabrication process. Dosimetric testing indicates that the 3D printed PSDs share many desirable properties with current commercially available PSDs such as dose linearity, dose rate independence, energy independence in the MV range, repeatability, and stability. These results demonstrate that not only does 3D printing offer a new avenue for the production and manufacturing of PSDs but also allows for further investigation into the application of 3D printing in dosimetry. Such investigations could include options for 3D printed, patient-specific scintillating dosimeters that may be used as standalone dosimeters or incorporated into existing 3D printed patient devices (e.g. bolus or immobilization) used during the delivery of radiation therapy.

Additive Manufacturing of High-Refractive-Index, Nanoarchitected Titanium Dioxide for 3D Dielectric Photonic Crystals

Additive manufacturing at small scales enables advances in micro- and nanoelectromechanical systems, micro-optics, and medical devices. Materials that lend themselves to AM at the nanoscale, especially for optical applications, are limited. State-of-the-art AM processes for high-refractive-index materials typically suffer from high porosity and poor repeatability and require complex experimental procedures. We developed an AM process to fabricate complex 3D architectures out of fully dense titanium dioxide (TiO₂) with a refractive index of 2.3 and nanosized critical dimensions. Transmission electron microscopy (TEM) analysis proves this material to be rutile phase of nanocrystalline TiO₂, with an average grain size of 110 nm and <1% porosity. Proof-of-concept woodpile architectures with 300-600 nm beam dimensions exhibit a full photonic band gap centered at 1.8-2.9 μm, as revealed by Fourier-transform infrared spectroscopy (FTIR) and supported by plane wave expansion simulations. The developed AM process enables advances in 3D MEMS, micro-optics, and prototyping of 3D dielectric PhCs.

Moldless Printing of Silicone Lenses With Embedded Nanostructured Optical Filters

Optical lenses are among the oldest technological innovations (3000 years ago) and they have enabled a multitude of applications in healthcare and in our daily lives. The primary function of optical lenses has changed little over time; they serve mainly as a light-collection (e.g. reflected, transmitted, diffracted) element, and the wavelength and/or intensity of the collected light is usually manipulated by coupling with various external optical filter elements or coatings. This generally results in losses associated with multiple interfacial reflections, and increases the complexity of design and construction. In this work we introduce a change in this paradigm, by integrating both light-shaping and image magnification into a single lens element using a moldless procedure that takes advantage of the physical and optical properties of mesoporous silicon (PSi) photonic crystal nanostructures. Casting of a liquid poly(dimethyl) siloxane (PDMS) pre-polymer solution onto a PSi film generates a droplet with contact angle that is readily controlled by the silicon nanostructure, and adhesion of the cured polymer to the PSi photonic crystal allows preparation of lightweight (10 mg) freestanding lenses (4.7 mm focal length) with an embedded optical component (e.g. optical rugate filter, resonant cavity, distributed Bragg reflector). Our fabrication process shows excellent reliability (yield 95%) and low cost and we expect our lens to have implications in a wide range of applications. As a proof-of-concept, using a single monolithic lens/filter element we demonstrate: fluorescence imaging of isolated human cancer cells with rejection of the blue excitation light, through a lens that is self-adhered to a commercial smartphone; shaping the emission spectrum of a white light emitting diode (LED) to tune the color from red through blue; and selection of a narrow wavelength band (bandwidth 5 nm) from a fluorescent molecular probe.

Active fluidic chip produced using 3D-printing for combinatorial therapeutic screening on liver tumor spheroid

Known for their capabilities in automated fluid manipulation, microfluidic devices integrated with pneumatic valves are broadly used for researches in life science and clinical practice. The application is, however, hindered by the high cost and overly complex fabrication procedure. Here, we present an approach for fabricating molds of active fluidic devices using a benchtop 3D printer and a simple 2-step protocol (i.e. 3D printing and polishing). The entire workflow can be completed within 6 h, costing less than US$ 5 to produce all necessary templates for PDMS replica molding, which have smooth surface and round-shaped pneumatic valve structures. Moreover, 3D printing can create unique bespoke on-off objects of a wide range of dimensions. The millimeter- and centimeter-sized features allow examination of large-scale biological samples. Our results demonstrate that the 3D-printed active fluidic device has valve control capacities on par with those made by photolithography. Controlled nutrients and ligands delivery by on-off active valves allows generation of dynamic signals mimicking the ever-changing environmental stimuli, and combinatorial/sequential drug inputs for therapeutic screening on liver tumor spheroid. We believe that the proposed methodology can pave the way for integration of active fluidic systems in research labs, clinical settings and even household appliances for a broad range of application.

A compact LED-based projection microstereolithography for producing 3D microstructures

Projection microstereolithography (PµSL) is a promising additive manufacturing technique due to its low cost, accuracy, speed, and also the diversity of the materials that it can use. Recently it has shown great potentials in various applications such as microfluidics, tissue engineering, micro-optics, biomedical microdevices, and so on. However, studies on PµSL are still ongoing in terms of the quality and accuracy of the construction process, which particularly affect the fabrication of complex 3D microstructures and make it attractive enough to be considered for commercial applications. In this paper, a compact LED-based PµSL 3D printer for the fabrication of 3D microstructures was developed, and the effective parameters that influence the quality of construction were thoroughly investigated and optimized. Accordingly, a customized optical system, including illumination optics and projection optics, was designed using optical engineering principles. This custom 3D printer was proposed for the PµSL process, which besides improving the quality of construction, led to the reduction of the size of the device, its cost-effectiveness, and the repeatability of its performance. To demonstrate the performance of the fabricated device, a variety of complex 3D microstructures such as porous, hollow, helical, and self-support microstructures were constructed. In addition, the repeatability of the device was assessed by fabricating microstructure arrays. The device performance showed that the lateral accuracy of printing was better than 5 μm, and the smallest thickness of the printed layer was 1 μm. Moreover, the maximum printable size of the device was 6.4 mm × 4 mm × 40 mm.

High-Resolution 3D Printing of Freeform, Transparent Displays in Ambient Air

Direct 3D printing technologies to produce 3D optoelectronic architectures have been explored extensively over the last several years. Although commercially available 3D printing techniques are useful for many applications, their limits in printable materials, printing resolutions, or processing temperatures are significant challenges for structural optoelectronics in achieving fully 3D-printed devices on 3D mechanical frames. Herein, the production of active optoelectronic devices with various form factors using a hybrid 3D printing process in ambient air is reported. This hybrid 3D printing system, which combines digital light processing for printing 3D mechanical architectures and a successive electrohydrodynamic jet for directly printing transparent pixels of organic light-emitting diodes at room temperature, can create high-resolution, transparent displays embedded inside arbitrarily shaped, 3D architectures in air. Also, the demonstration of a 3D-printed, eyeglass-type display for a wireless, augmented reality system is an example of another application. These results represent substantial progress in the development of next-generation, freeform optoelectronics.

Silica optical fiber drawn from 3D printed preforms

Silica optical fiber was drawn from a three-dimensional printed preform. Both single mode and multimode fibers are reported. The results demonstrate additive manufacturing of glass optical fibers and its potential to disrupt traditional optical fiber fabrication. It opens up fiber designs for novel applications hitherto not possible.

3D Nanoprinting of Perovskites

As competing with the established silicon technology, organic-inorganic metal halide perovskites are continually gaining ground in optoelectronics due to their excellent material properties and low-cost production. The ability to have control over their shape, as well as composition and crystallinity, is indispensable for practical materialization. Many sophisticated nanofabrication methods have been devised to shape perovskites; however, they are still limited to in-plane, low-aspect-ratio, and simple forms. This is in stark contrast with the demands of modern optoelectronics with freeform circuitry and high integration density. Here, a nanoprecision 3D printing is developed for organic-inorganic metal halide perovskites. The method is based on guiding evaporation-induced perovskite crystallization in mid-air using a femtoliter ink meniscus formed on a nanopipette, resulting in freestanding 3D perovskite nanostructures with a preferred crystal orientation. Stretching the ink meniscus with a pulling process enables on-demand control of the nanostructure's diameter and hollowness, leading to an unprecedented tubular-solid transition. With varying the pulling direction, a layer-by-layer stacking of perovskite nanostructures is successfully demonstrated with programmed shapes and positions, a primary step for additive manufacturing. It is expected that the method has the potential to create freeform perovskite nanostructures for customized optoelectronics.

Ultrafast Three-Dimensional Printing of Optically Smooth Microlens Arrays by Oscillation-Assisted Digital Light Processing

A microlens array has become an important micro-optics device in various applications. Compared with traditional manufacturing approaches, digital light processing (DLP)-based printing enables fabrication of complex three-dimensional (3D) geometries and is a possible manufacturing approach for microlens arrays. However, the nature of 3D printing objects by stacking successive 2D patterns formed by discrete pixels leads to coarse surface roughness and makes DLP-based printing unsuccessful in fabricating optical components. Here, we report an oscillation-assisted DLP-based printing approach for fabrication of microlens arrays. An optically smooth surface (about 1 nm surface roughness) is achieved by mechanical oscillation that eliminates the jagged surface formed by discrete pixels, and a 1-3 s single grayscale ultraviolet (UV) exposure that removes the staircase effect. Moreover, computationally designed grayscale UV patterns allow us to fabricate microlenses with various profiles. The proposed approach paves a way to 3D print optical components with high quality, fast speed, and vast flexibility.

3D-printed chiral metasurface as a dichroic dual-band polarization converter

We propose a novel design of a 3D chiral metasurface behaving as a spatial polarization converter with asymmetric transmission. The metasurface is made of a lattice of metallic one-and-a-half-pitch helical particles. The proposed metasurface exhibits a dual-band asymmetric transmission accompanied by the effect of complete polarization conversion. Regarding circularly polarized waves, the metasurface demonstrates a strong circular dichroism. A prototype of the metasurface is manufactured for the quasi-optic experiment by using a 3D printing technique utilizing a cobalt-chromium alloy, which exhibits good performances against thermal fatigue and corrosion at high temperatures.