Researchers Develop Single-Photon Method for Large-Scale, Laser-Based 3D Nanoprinting

Researchers in Purdue University’s College of Engineering have developed patent-pending single-photon 3D nanoprinting technology. The process can produce a higher throughput of complex, high-resolution nanostructures faster and less expensively than traditional laser-based 3D additive nanoprinting technologies.

Liang Pan, professor of mechanical engineering, leads the team developing the technology that enables 3D nanoprinting at lower laser intensities without the need for femtosecond lasers. The technology does not rely on single-point scanning processes and therefore produces high-speed and high-resolution results.

“The technology uses less expensive light sources as simple as a laser pointer, which can reduce the tool cost by 10 to 100 times,” he says. “The writing speed is a few orders of magnitude faster for each beam, and we can further expand to parallel scan with tens to hundreds of beams.”

The single-photon technology has applications in nanotechnology research and industry, manufacturing processes and health care.

Drawbacks of Traditional Nanoprinting

Femtosecond laser two-photon polymerization is widely used for 3D nanostructure fabrication. “However, this technique is expensive and slow, which presents significant obstacles for commercial use in manufacturing,” Pan says.

Researchers says that alternative options have been developed to increase speed and reduce cost, but they deliver limited resolution and require high-power lasers, unlike Pan’s innovation.

Validating the Purdue Method

Pan’s single photon-based method uses fast panel writing to construct high-volume and complex nanostructures for wide ranges of use. Notable applications include nanolithography, zero-stiffness microstructures and thermal interface structures.

“We have demonstrated the method by printing 120-nm resolution structures using a low-cost diode laser,” Pan says. “We also demonstrated parallel nanoprinting using a nine-by-nine array laser beam.”

The next steps to develop the technology are further increasing the scanning throughput and reducing the tool cost. Pan and his team are applying for federal funds for research and development. The National Science Foundation has already awarded Pan two grants to conduct his research.

Commercializing the Process

Pan disclosed the 3D nanoprinting technology to the Purdue Innovates Office of Technology Commercialization, which has applied for patents to protect the intellectual property. Industry partners interested in developing or commercializing it should contact Parag Vasekar, business development and licensing manager, at psvasekar@prf.org, track code 69873.

The Purdue Innovates Office of Technology Commercialization says it operates one of the most comprehensive technology transfer programs among leading research universities in the U.S. Its services support the economic development initiatives of Purdue University and benefit the university’s academic activities through commercializing, licensing and protecting Purdue intellectual property. In fiscal year 2024, the office reported 145 deals finalized with 224 technologies signed, 466 invention disclosures received and 290 U.S. and international patents received. The office is managed by the Purdue Research Foundation, a private, nonprofit foundation created to advance the mission of Purdue University.