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Geometric determinants of sinterless, low-temperature-processed 3D-nanoprinted glass.

Adira Colton1, Ryan N Halli1, M Rho Ma1,2

  • 1Department of Mechanical Engineering, University of Maryland, College Park, MD, 20742, USA.

Microsystems & Nanoengineering
|July 17, 2025
PubMed
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Three-dimensional (3D) printing of fused silica glass using two-photon direct laser writing (DLW) shows feature size impacts optical and mechanical properties. Thicker 3D-printed glass microstructures exhibit reduced transparency and mechanical strength, limiting applications.

Area of Science:

  • Materials Science
  • Optical Engineering
  • Mechanical Engineering

Background:

  • Glass materials are crucial for microsystems in optics, photonics, microfluidics, and biomedicine.
  • Additive manufacturing, specifically three-dimensional (3D) printing, offers new possibilities for glass micro/nanotechnologies.
  • Two-photon direct laser writing (DLW) of polyhedral oligomeric silsesquioxanes (POSS)-based resins enables sinterless, low-temperature 3D printing of fused silica glass.

Purpose of the Study:

  • To investigate how the feature size of DLW-printed glass microstructures affects their optical and mechanical properties.
  • To establish critical benchmarks for the use of 3D-printed POSS-based fused silica glass in emerging applications.

Main Methods:

  • Utilized two-photon direct laser writing (DLW) to fabricate fused silica glass microstructures from POSS-based resins.

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  • Experimentally assessed optical transparency of DLW-printed microlenses at varying feature sizes.
  • Conducted compressive loading tests on hollow glass cylindrical microstructures to determine mechanical properties (e.g., Young's modulus) as a function of wall thickness.

    • Main Results:

    • Optical transparency remained comparable up to 40 µm feature thickness, but significantly decreased at 60 µm (87.87% to 63.57%).
    • Mechanical performance, specifically Young's modulus, remained consistent up to 30 µm wall thickness, then degraded substantially (251.6 MPa to 99.7 MPa between 30 µm and 40 µm).
    • Successfully fabricated and demonstrated POSS-based glass microneedle arrays (MNAs) for biomedical microinjection applications, leveraging the established property benchmarks.

    Conclusions:

    • DLW-printed fused silica glass microstructures exhibit size-dependent optical and mechanical properties.
    • Feature size is a critical determinant influencing the performance limits of these 3D-printed glass components.
    • This study provides essential data for designing and utilizing 3D-printed glass microstructures in advanced applications, including biomedical devices.