Single-Photon 3D Nanolithography Parallel Volumetric Polymerization

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Solution Overview

Problem

Current 3D nano-printing technologies face significant challenges with high costs, low throughput, and limited resolution, making them unsuitable for mass production and commercial use.

Innovation Solution

The development of high-resolution, low-cost, high-throughput single-photon 3D nanolithography systems and methods, which utilize an initiation-depletion-based mechanism to achieve nonlinear polymerization, enabling the direct-writing of sophisticated 3D nanostructures at significantly improved speeds and resolutions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If femtosecond laser-based two-photon polymerization is used to produce 3D nanostructures, then nanoscale feature resolution is achieved, but throughput is slow due to point-by-point scanning processes

Engineering Contradiction:

Improvenanoscale feature resolutionVSAvoidthroughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent segments the illumination process into multiple wavelength components that can be independently controlled and directed to different spatial locations simultaneously, enabling parallel processing of multiple voxels rather than sequential point-by-point scanning

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple wavelength lights (e.g., 405nm, 450nm, 473nm) to simultaneously excite different photoinitiators in different regions, merging their effects to achieve volumetric polymerization throughout the resin depth, thereby increasing throughput while maintaining nanoscale resolution

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If conventional 3D nano-printing systems are used, then nanoscale structures can be fabricated, but the cost is extremely high (over $500,000 per unit)

Engineering Contradiction:

Improvenanoscale structure fabrication capabilityVSAvoidsystem cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive femtosecond laser systems with inexpensive continuous-wave diode lasers that can be purchased for thousands rather than hundreds of thousands of dollars, sacrificing neither resolution nor capability but dramatically reducing system cost for commercial viability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the fundamental operating parameters by using multiple lower-power wavelength-specific photoinitiators instead of a single high-power femtosecond laser, allowing the use of cheap diode lasers while achieving the same polymerization effect through cumulative exposure

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If point-by-point scanning processes are used for 3D nano-printing, then precise control is achieved, but the printing speed is slow

Engineering Contradiction:

Improveprecise spatial controlVSAvoidprinting speed

Core Design Contradiction:

Measurement precisionVSSpeed

Solution Approach 1:

The patent transitions from one-dimensional sequential scanning to three-dimensional parallel volumetric illumination by using multiple wavelengths that penetrate to different depths and can be independently patterned, enabling simultaneous polymerization throughout the entire build volume

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent enables continuous volumetric polymerization throughout the resin by simultaneously activating photoinitiators at multiple depths with different wavelengths, eliminating the need for sequential layer-by-layer or point-by-point processing and achieving continuous useful action throughout the build volume

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

These systems achieve a 1000-times higher throughput and 1000-times lower process cost compared to existing methods, while maintaining or exceeding the patterning resolution of current technologies, thereby enabling the scalable manufacturing of 3D nanostructures.

Implementation Method 1

exciting a photoinitiator molecule from a photoinitiator ground state to an excited photoinitiator singlet state, transitioning the photoinitiator molecule from the photoinitiator singlet state to an excited photoinitiator triplet state... exciting the photoinitiator molecule to thereby generate a free radical configured to initiate polymerization

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

initiating a triplet-triplet energy transfer process to excite the photoinitiator molecule at the excited photoinitiator triplet state using energy from the sensitizer molecule at the excited sensitizer triplet state

Methodology Applied

Scientific EffectEnergy transfer:

Data Source

PatentUS20250073989A1Nanoscale single photon three-dimensional printing systems and methods

Publication Date: 2025.03.06 PURDUE RES FOUND

AI summary

A method of additive manufacturing includes directing a first photon beam onto a resin and directing a second photon beam onto the resin to generate a reactive species from the initiator molecule to thereby polymerize a portion of the resin. The resin includes an initiator molecule and a sensitizer molecule. The first photon beam simultaneously excites each of the initiator molecule and the sensitizer molecule, transitions each of the initiator molecule and the sensitizer molecule into their respective singlet excited states; and transfers, at least one of energy or electrons, from the singlet excited state of the sensitizer molecule to the initiator molecule.