In an exciting development for the field of additive manufacturing, UpNano GmbH has co-developed a novel process that leverages modified two-photon polymerization (2PP) to create high-resolution, 3D-printed fused quartz objects. This innovation, developed in collaboration with Glassomer GmbH, offers the ability to produce complex glass components in the millimeter and centimeter range, a significant leap in the capabilities of 3D printing technology.The Challenge of 3D Printing with Fused SilicaManufacturing intricate 3D objects from glass, particularly high-quality fused silica (SiO₂), presents a myriad of challenges. Fused silica has an exceptionally high melting point, and traditional methods for creating glass components often rely on non-commercial equipment. Techniques such as melting glass fibers with laser beams or employing fused deposition modeling to produce soda-lime glass are common but come with significant drawbacks, including the creation of rough surface finishes that are unsuitable for many applications.Recognizing these challenges, UpNano and Glassomer set out to develop a rapid 3D printing process that can produce smooth fused silica parts with micro-scale features, paving the way for a new era of high-precision glass manufacturing.The 3D Printing Process: A Three-Step ApproachThe innovative manufacturing process developed by UpNano involves three key steps:Design and Print the Structure: Utilizing the advantages of 2PP technology, the first step involves designing and printing the desired structure. This technique allows for the creation of intricate geometries with high fidelity.Remove the Organic Binder: After printing, the next step is to remove the organic binder material from the printed object. This step is crucial for ensuring the integrity of the final product.High-Temperature Sintering: Finally, the structure undergoes a high-temperature sintering process, where it is heated to 1,300°C. This step fuses the SiO₂ nanoparticles together, resulting in the final fused silica product.At the core of this process is a newly developed nanocomposite known as UpQuartz. This innovative material not only contains SiO₂ nanoparticles but also incorporates a specially designed polymer matrix that facilitates the 2PP printing process. Initially, the printed structure is referred to as a "green part," which retains the shape of the final desired object. The polymer matrix is subsequently removed by heating the green part to 600°C, leaving behind a “brown part” composed entirely of SiO₂ nanoparticles.Characteristics of the Final ProductOnce the printed structure has undergone the necessary thermal processing, it achieves a high degree of optical clarity and mechanical strength. For instance, a recent application involved creating a fused silica filter element with 180 µm pores, measuring 3.6 mm in length and 875 µm in inner diameter. Such components exhibit excellent temperature resistance and can withstand harsh chemical conditions, making them suitable for demanding applications in various fields.Applications and Future ProspectsThe implications of this innovative production process are vast. It is ideally suited for producing larger 3D-printed glass parts that demand high-resolution and precision, particularly in engineering, chemical, medical, and research applications. The unique properties of fused silica, including its superior optical characteristics, biocompatibility, and high chemical inertness, make it a desirable material across these sectors.According to Markus Lunzer, team lead of Materials & Application at UpNano, “This innovative production process we developed is ideally suited for larger 3D-printed glass parts that require high-resolution and high-precision.”In addition to this latest advancement, UpNano has also leveraged its printers to produce complex embedded microfluidic chips, as well as tungsten and platinum microstructures with sub-micrometer resolution. This versatility underscores the potential of UpNano’s technology to transform various industries by enabling the mass production of highly precise parts.ConclusionAs UpNano continues to refine its processes and expand its range of materials, the company is positioned to be at the forefront of the 3D printing revolution. The development of this modified two-photon polymerization process not only marks a significant milestone in the additive manufacturing of glass but also opens the door to a wide array of applications that can benefit from the unique properties of fused silica.As Bernhard Küenburg, CEO of UpNano, states, “The speed, resolution, and versatility of our printers make them powerful tools for the mass production of highly precise parts. Our ever-expanding range of materials extends the range of applications. In due course, we will also expand the range of services we offer.”The future of high-resolution additive manufacturing is bright, and UpNano is leading the charge towards new possibilities in material design and production.
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