Generally speaking, in manufacturing, most innovations are developed around the ability to produce large 3D printed parts. However, with the growing demand for miniaturized equipment in electronics, biotechnology, automotive and aerospace, interest in micro-additive manufacturing technology is increasing. So, how big is the market for small parts? In this issue, combined with the analysis of Nanoscribe's business development manager Jörg Smolenski, the 3D Science Valley joins Guyou to understand the basic principles and different types of micro-additive manufacturing technology, as well as the main advantages of micro-additive manufacturing technology that helps the market move forward and areas that need improvement.
micro3D printing technology
© NanoScribe
Irreversible
micro-additive manufacturing is usually used interchangeably with 3D micro-processing or high-precision additive manufacturing, but in fact, they are not exactly synonyms. Generally, additive manufacturing refers more to the industrial manufacturing environment, and 3D micromachining is a general term for describing all methods, such as the lithography method that is very common and widely used in MEMS manufacturing (which is a huge mature market and very mature method). There are many other 3D micromachining methods, such as methods for microfluidics, digital methods based on electron beam lithography, and more.
To illustrate the status of micro-additive manufacturing technology, assume that in 3D printing, a part is first constructed and digitized through a dot array, where a dot (i.e., voxel ) represents a minimum printing unit. Voxel sizes range from nano-scale to macro-scale. Therefore, the micro 3D printing process requires the use of micron or submicron voxels, which is crucial for the manufacturing of micro products. Therefore, the term micro 3D printing refers to the manufacturing of ultra-high precision, tiny parts that are shapes that cannot be achieved using micro injection molding and other types of traditional manufacturing processes.
According to the Valley of 3D Science, there are two focus points in the development of 3D printing technology, one of which is large-format 3D printing technology. Another focus is on the microscopic aspect, namely 3D printing technology that can make precision, fine devices. Micro-nano 3D printing can create complex and fine devices, which is a reflection of the advantages of 3D printing technology and may subvert the precision device manufacturing industry.
The tiny power is changing the world! 3D Science Valley has shared that the core technology of micron-scale 3D printing company Cytosurge comes from ETH Zurich University of Technology in Zurich. It develops, manufactures and sells innovative high-precision nanotechnology metal 3D printers based on its patented FluidFM technology. This technology represents fluid force microscopy technology and has many applications in life sciences and biophysics .
China, West Lake Future Intelligent Manufacturing Three-dimensional Precision Manufacturing Technology with Micron-Scale Precision, makes up for the market gap between 100 nanometers and 100 micrometers in precision processing in electronic and optical fields by integrating metals, ceramics, magnetic materials, polymers, etc.
When the part measures the layer thickness of 5 microns and the resolution of 2 microns in single digits, it enters the process of processing micro 3D printing. Interestingly, some micro-additive manufacturing processes can make parts measured in nanometers (nm), 1,000 times smaller than one micrometer. To better visualize what this level of micromanufacturing looks like, for example, one will usually remember that the average width of human hair is 75 microns, while the diameter of human DNA strands is 2.5 nanometers.
In miniaturization, the control of external dimensions is crucial, and micro 3D printing can achieve the "next level" miniaturization. Specifically: electronics, optics, semiconductors, medical devices, medical tools, micro injection molding, microfluidics, sensors and other applications are areas where micro 3D printing plays its unique value.
For example, high-precision 3D bioprinting can be customized scaffolds for tissue engineering, for cell research, and is suitable for many other innovative biomedical that require precision, speed, material diversity and sterility. 3D micromachining can bring life science research closer to the concept of regenerative medicine to treat diseases in the field.For example, scientists at Boston University have developed a soft and mechanically active cell culture platform through a microfluidic chip platform made by two-photon polymerization (2PP) for studying myocardial tissue in a customizable 3D microenvironment. This cell culture platform allows heart tissue to grow in a 3D environment and its self-assembly can be observed at cell attachment sites on the vertical wall of the chip. Integrated electronic sensors measure the forces generated by the contraction of cultured heart cells. In addition, the researchers integrated a mechanical actuator into the chip, and with this actuator, the scientists studied the effects of constant and dynamic mechanical strain on cardiac tissue. Many other exciting applications of micro 3D printing in tissue engineering, cell biology, and regenerative medicine can be expected.
Quantum X's integrated two-photon grayscale lithography (2GL®) and its base voxel tuning technology are able to create 2.5D microstructures with submicron shape accuracy and surface roughness of less than 5 nanometers (Ra).
© NanoScribe
Generally speaking, we believe that 10 microns and below are micro-additive manufacturing. Of course, if all of this is in the 1-3 micron range, then this is the most accurate definition of micro-AM.
Just like there are several types of AM processes, there are also various types of micro-AM processes, including: fuse deposition (FFD), direct ink writing (DIW), direct energy deposition (DED), laminated object manufacturing (LOM), electrohydrodynamic redox printing (EHDP), powder bed melting (PBF), photopolymerization-based 3D printing (P3DP), and laser chemical vapor deposition (LCVD).
Micro 3D printing technology
© 3D Science Valley White Paper
Resin-based micro 3D printing process is currently the most recognized process on the market due to its advantages in resolution, quality, reproducibility and speed. In addition, DED and EHDP can achieve higher resolutions. However, the expensive costs and low manufacturing rates associated with these processes limit their application. However, due to limited resolution, they still have limitations in achieving small, high-precision parts or structures.
Nanoscribe's 2PP is able to make minimum feature sizes as low as 100 nanometers compared to these methods. According to the research, the development of new optical methods has led to advances in micro-additive manufacturing processes, especially 3D printing processes based on photopolymerization. According to experts, using light sources with shorter wavelengths (such as UV beams) and objectives with higher NA (numerical aperture) can achieve higher resolutions – which is often one of the most prominent challenges in micro-AM.
Optical methods make the connection of adjacent voxels stronger than other methods based on heat treatment and lamination. Post-processing steps such as photocuring can also help improve the quality of 3D printed parts. Finally, the report states that laser spots or optical patterns of the processed feedstock help improve stability and repeatability due to the non-contact mode between the processing area and the lighting system.
Which, the most well-known micro-additive manufacturing processes include DLP, micro-stereoscopic lithography (μSLA), projected micro-stereoscopic lithography (PμSL), two-photon polymerization (2PP or TPP), photolithography-based metal manufacturing (LMM), electrochemical deposition and micro-scale selective laser sintering (μSLS).
Direct Light Projection (DLP) technology
DLP technology combines DLP with the use of adaptive optics to achieve repeatable micron-scale resolution. One of the main differences to what is commonly referred to as SLA is that SLA requires laser to track one layer, while DLP uses a projection light source to cure the entire layer at once.
microstereoscopic lithography (μSLA)
is also manufactured based on light-induced layer stacking, microstereoscopic lithography (MPuSLA) is used to construct physical components by exposing photosensitive polymer resin to ultraviolet laser.
Projection Microstereoscopic Lithography (PμSL)
PμSL is a high-resolution (up to 0.6 μm) 3D printing technology based on region projection triggered light polymerization, capable of manufacturing complex 3D architectures covering multiple scales and multiple materials. Machines based on this process are often thought to combine the advantages of DLP and SLA technologies. The process has developed rapidly due to its affordability, accuracy, speed and ability to process polymers, biomaterials and ceramics.
Lithography-based metal fabrication
After uniform dispersion in photosensitive resin , the metal powder is then selectively polymerized by exposure with blue light. The 3D printed green parts are then sintered in the furnace to obtain dense parts.
Two-photon polymerization (2PP or TPP)
This process is generally considered to be the most accurate in micro 3D printers. 2PP is a direct laser writing method that allows for the steps of working 3D and 2.5D microstructures without expensive mask generation and multiple lithography. It can be said that 2PP has achieved its full potential between maskless lithography and high-precision additive manufacturing.
According to the market understanding of 3D Science Valley, 2PP has promoted the micromanufacturing of parts on wafer-level planar substrates, for example, in the application fields of optical fiber , photonic chip and internally sealed microfluidic channel.
2PP requires special photosensitive resins for easy processing, optimal resolution and shape accuracy, and tailored for different applications. Currently, high-precision 3D printing based on two-photon polymerization is very suitable for rapid prototyping in application design for biomedical equipment, microoptical, microelectromechanical systems (MEMS), microfluidic equipment, photon packaging (e.g. PIC), surface engineering projects, and more. wafer processing capability makes batch processing and small batch production of 3D micro-parts easier than ever.
Electrochemical deposition
Electrochemical deposition is a rare miniature 3D printing technology that does not require any post-processing. The process uses a small print nozzle called an ion tip and immerse it in a supporting electrolyte bath. The regulated air pressure pushes the liquid containing metal ions through the microchannels within the ion tip. At the end of the microchannel, the ions-containing liquid is released onto the printing surface. The dissolved metal ions are then electrodeposited into solid metal atoms. The latter then grows into larger building blocks (voxels) until the parts are formed.
Microscale Selective Laser Sintering (μSLS)
This powder bed fusion-based additive manufacturing, also known as micron-scale selective Laser Sintering (SLS), involves coating a substrate with a layer of metal nanoparticle ink and then drying it to create a uniform nanoparticle layer. Thereafter, the laser sinters the nanoparticles into the desired pattern. The process is then repeated until the part is created.
fascinating small parts
With the advancements in new processing technologies such as two-photon grayscale lithography (2GL ®) and the combination of higher power lasers on the market with improved hardware such as stages and scanners, the status quo of micro-additive manufacturing has changed. In contrast, other more traditional additive manufacturing techniques such as DLP, SLA and projection microstereoscopic lithography (PμSL) can only make larger structures, however, they encounter geometric limitations when it comes to high resolution (1 micron) 3D micromachining. Due to the inherent direct illumination of UV light, resolution and design of geometry are limited.
According to market observations from 3D Science Valley, Nanoscribe offers a novel industrial solution for photonic packaging with the recently launched Quantum X align. Coupling loss is reduced by component-level rather than chip-level pattern field matching. High precision with nano-accurate automatic alignment 3D printing drives the fabrication of microoptical components directly on photonic chips and fiber cores and prints free-surface microoptical components or diffraction optical components (DOEs) directly in place, thereby facilitating optimized optical coupling on photonic platforms.
Nanoscribe’s proprietary two-photon grayscale lithography (2GL ®) significantly accelerates high-precision micromachining of 2.5D structures for optical applications, such as with the highest shape accuracy and optical-grade surfaces (Ra ≤ 5 nm). To further expand production scale, Nanoscribe has piloted two reliable and proven replication strategies with EV Group and kdg opticomp.
Like any 3D printing process, micro 3D printing allows its users to benefit from design freedom. A challenge in the fields of photonic integration, optical computing and data communication is to advance the alignment and packaging of photonic components. Specialized hardware and software-based 3D printing solutions enable efficient micro-optical coupling.
The speed at which a small part is made is fascinating compared to the same parts made through traditional manufacturing processes. With the advancement of miniaturized micro products, micro 3D printing is suitable for all industries that handle small and precision parts. Traditionally, the cost of manufacturing small parts has been high, and micro-additive manufacturing is now offering cheaper and easier to use solutions.
Knows it deeply, and moves it far. Based on the globally sophisticated network of manufacturing experts’ think tanks, 3D Science Valley provides the industry with a global perspective on the in-depth observation of additive and intelligent manufacturing. For more analysis in the field of additive manufacturing, please pay attention to the white paper series released by 3D Science Valley.
Website Submission l Send to [email protected]
