UpNano GmbH, based in Vienna, Austria, has co-developed an innovative manufacturing process for 3D-printed fused quartz objects. This groundbreaking technology allows the production of high-precision shaped parts ranging from millimeters to centimeters.
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The process leverages Glassomer GmbH’s innovation and adapts it for two-photon polymerization (2PP) 3D-printing using UpNano’s NanoOne high-resolution printing system. These state-of-the-art 2PP printers are among the highest performing on the market, capable of printing with resolutions spanning more than 15 orders of magnitude.
Manufacturing complex 3D objects in glass is challenging, particularly when using high-quality fused silica (SiO2) glass, which has a high melting point. Traditional methods, which include melting glass fibers with lasers or using fused deposition modeling to produce soda lime glass, often yield rough surfaces that are less desirable. UpNano and Glassomer’s new rapid 3D printing process can produce smooth fused silica parts with high-resolution features in the micrometer range.
Markus Lunzer, team lead of Materials & Application at UpNano, explains the three-step process: “First, design and print the desired structure using the advantages of 2PP 3D-printing. Second, remove the organic binder material. Third, sinter the structure at high temperatures.”
The Process Developed by UpNano
The core of this process is a new nanocomposite called “UpQuartz,” which includes SiO2 nanoparticles and a specially designed polymer matrix that enables 2PP 3D-printing. This process produces a “green part” that has the final desired shape. To achieve the final fused silica product, the polymer matrix is removed by heating the green part to 600°C, resulting in a “brown part” made of SiO2 nanoparticles. The structure is then sintered at 1,300°C, fusing the particles.
During post-processing, the object undergoes isotropic shrinkage of about 30%, which can be compensated for by upscaling the green part using UpNano’s software. Lunzer highlights the process’s suitability for creating larger 3D-printed glass parts with high resolution and precision, benefiting fields such as engineering, chemical, medical, and research applications.
Fused silica offers superior optical properties, biocompatibility, high chemical inertness, and exceptional heat resistance, making it ideal for a wide range of applications. This new development marks a significant advancement in the potential of 2PP 3D printing, following UpNano’s recent successes in advancing material testing of 2PP 3D-printed parts and achieving milestones in producing holistic embedded microfluidic chips and tungsten and platinum microstructures with sub-micrometer resolution.
The development of fused silica 3D printing by 2PP was a joint effort between UpNano and Glassomer. Glassomer has previously enabled the production of fused silica objects through technologies such as soft lithography, injection molding, and conventional 3D printing. The collaboration now allows high-precision 2PP 3D printing of fused silica objects.
These advancements showcase UpNano’s innovation in the competitive 2PP 3D-printer market, along with the growing commercial success of the NanoOne printer range, which saw a 57% increase in sales in 2023. UpNano now serves customers on five continents.
“The speed, resolution, and versatility of our printers make them powerful tools for mass-producing highly precise parts. Our ever-expanding range of materials extends the range of applications. We will also expand our range of services in due course,” adds Bernhard Küenburg, CEO of UpNano.
All NanoOne printers feature patented adaptive resolution technology, which allows the laser beam to be expanded by a factor of 10 for any given objective. A recent software update has enabled seamless stitching, making the NanoOne range of printers the most versatile and fastest 2PP 3D-printers available.
