Novel process for 3D-printing macro-sized fused silica parts with hi-res features

UpNano GmbH in Vienna, Austria, has co-developed a novel manufacturing course of for 3D-printed fused quartz objects. This modern know-how permits the manufacturing of high-precision formed elements within the mm and cm vary.

The method is predicated on Glassomer GmbH’s (Freiburg, Germany) innovation and has been modified for two-photon polymerization (2PP) 3D-printing utilizing UpNano’s NanoOne high-resolution printing system. These are the very best efficiency 2PP 3D-printers in the marketplace, able to printing greater than 15 orders of magnitude.

Manufacturing minuscule and complicated 3D objects in glass is a difficult course of. It’s much more difficult if the required materials is to be high-quality fused silica (SiO₂) glass, which has an exceptionally excessive melting level. The one potential strategies that can be utilized are based mostly on non-commercially accessible tools and embody melting glass fibers utilizing laser beams or fused deposition modeling to provide soda lime glass.

These strategies usually lead to remaining merchandise with tough surfaces which can be undesirable. Now, UpNano and Glassomer have developed a speedy 3D printing course of to provide clean fused silica elements within the mm and cm vary with options within the μm vary.

“It is a three-step course of,” explains Markus Lunzer, staff lead of Supplies & Software at UpNano. “Step one is to design and print the specified construction utilizing all the benefits 2PP 3D-printing provides. The second step is to take away natural binder materials adopted by a excessive temperature sintering course of, the third step.”

On the core of this can be a newly developed nanocomposite “UpQuartz.” Along with SiO₂ nanoparticles, it incorporates a specifically designed polymer matrix that permits the composite to be 2PP 3D-printed within the first place. The printing course of produces a “inexperienced half” that already has the form of the ultimate and desired construction.

To acquire the fused silica product in the long run, the polymer matrix should be eliminated. Heating the inexperienced half to 600°C successfully removes the polymer matrix, abandoning the “brown half.” This consists of SiO₂ nanoparticles within the form of the ultimate product. The construction is sintered and fused after publicity to 1,300°C.

Throughout post-processing, the item undergoes isotropic shrinkage of roughly 30%. This may simply be compensated for by an applicable upscaling of the inexperienced half utilizing UpNano’s software program.

“This modern manufacturing course of we developed,” says Lunzer, “is ideally suited to bigger 3D-printed glass elements that require high-resolution and high-precision, within the fields of engineering, and chemical, medical or analysis purposes.”

Fused silica provides superior optical properties, together with biocompatibility in addition to excessive chemical inertness and distinctive warmth resistance, making it a really perfect materials for an enormous vary of purposes. This new growth marks a major development within the potential of 2PP 3D printing, following UpNano’s latest success in advancing the fabric testing of 2PP 3D-printed elements utilizing UpNano printers and resins for macroscopic take a look at specimens.

As well as, the corporate’s printers have not too long ago been used to attain a major milestone in 2PP 3D-printing by producing holistic embedded microfluidic chips in addition to tungsten and platinum microstructures with (sub-)μm decision.

The manufacturing of fused silica objects by 2PP 3D printing was a joint growth between UpNano and Glassomer. The German firm has beforehand enabled the manufacturing of fused silica objects by using applied sciences equivalent to smooth lithography, injection molding, in addition to typical 3D-printing. Now, the joint materials growth from UpNano and Glassomer additionally permits the usage of high-precision 2PP 3D-printing to provide fused silica objects.

This sequence of developments exemplifies UpNano’s innovation capital within the extremely aggressive 2PP 3D-printer market, complemented by the continued and rising industrial success of the NanoOne printer vary. In truth, gross sales in 2023 have been up 57% on the earlier 12 months and prospects at the moment are served on 5 continents.

All NanoOne printers are outfitted with patented adaptive decision know-how, which permits the laser beam to be expanded by an element of 10 for any given goal. A latest software program replace has enabled seamless stitching, and given all of the accessible modules, the NanoOne vary of printers is now thought-about probably the most versatile and quickest 2PP 3D-printer in the marketplace.

“The pace, decision, and flexibility of our printers make them highly effective instruments for the mass manufacturing of extremely exact elements. Our ever-expanding vary of supplies extends the vary of purposes. Sooner or later, we may also develop the vary of companies we provide,” provides Bernhard Küenburg, UpNano’s CEO.

Supplied by
UpNano GmbH