Dual-head multi-photon polymerization 3D printing for parallel additive manufacturing organic/inorganic materials in optics

Abstract

Rapid 3D laser printing based on two-photon polymerization (TPP) is a promising technique for fabricating high-resolution structures, but its scalability is often hindered by challenges in parallelization and material versatility. In this study, we present a high-precision, multi-head 3D printing system that integrates advanced optical and material control to address these limitations. By employing a dual-head setup with independent focal length adjustments and paired linear polarizers, our system enables simultaneous multi-material printing and rapid iteration of fabrication parameters, significantly enhancing prototyping efficiency. We demonstrated this system's versatility by successfully fabricating diverse microstructures, and compatible with organic and inorganic components. The system can achieve a minimum feature size of sub-100 nm and the highest printing speeds of 20 mm/s with a numerical aperture (NA) of 1.3 or 0.8, balancing precision and efficiency for industrial-scale applications. Additionally, its capability to perform multi-parameter, full-field-of-view additive manufacturing facilitates a wide range of design possibilities. The potential of this technique is further illustrated through two optical applications: an 8 × 8 convex lens array and diffractive optics for high-resolution holography. The lenses exhibit exceptional surface quality and uniformity with a roughness of less than 4 nm and a peak-to-valley surface deviation is around 200 nm, while the diffractive optics achieve sub-wavelength feature resolution, demonstrating the system’s suitability for advanced optical component manufacturing. This study advances the state of additive manufacturing by addressing key challenges in parallelization, scalability, and material diversity.