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Related Experiment Video

Updated: Jun 26, 2026

Micro 3D Printing Using a Digital Projector and its Application in the Study of Soft Materials Mechanics
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Grayscale Digital Light Processing 3D Printed Microlens for Scale-Down Self-Focusing Printing.

Lei Xu1,2, Kunhao Wang2, Haoyu Liu2

  • 1Guangdong Provincial Key Laboratory for Processing and Forming of Advanced Metallic Materials, South China University of Technology, Guangzhou, 510640, China.

Small (Weinheim an Der Bergstrasse, Germany)
|September 10, 2025
PubMed
Summary

This study introduces a novel microlens self-focusing printing technique for high-precision 3D microfabrication. The method achieves sub-4µm feature sizes and enables complex composite microstructure printing, advancing micro/nano fabrication capabilities.

Keywords:
DLP 3D printing microlensgrayscale‐based photopolymerizationmicro/nano fabricationoptical microscope platformself‐focusing printing

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Area of Science:

  • Micro/nano fabrication
  • Additive manufacturing
  • Optical engineering

Background:

  • Existing 3D printing technologies face limitations in precision and efficiency for microstructures.
  • Fabricating composite 3D microstructures with high accuracy remains a challenge.

Purpose of the Study:

  • To develop a novel microlens self-focusing printing technique for high-precision microfabrication.
  • To overcome the limitations of current 3D printing methods in producing complex microstructures.

Main Methods:

  • Integration of digital light processing (DLP) 3D printing with an optical microscope platform.
  • Utilizing controlled image grayscale for millisecond-level single-exposure microlens fabrication.
  • Leveraging the self-focusing property of microlenses for sub-4µm pattern printing.

Main Results:

  • Microlenses with precise optical focusing capabilities were fabricated.
  • Achieved pattern printing with feature sizes below 4 µm without additional hardware.
  • Successfully fabricated composite tetrahedral magnetic microrobots with controlled dynamic motion.

Conclusions:

  • The proposed microlens self-focusing printing technique offers a simple and versatile approach for high-precision microstructure fabrication.
  • This method enhances process efficiency and precision in micro/nano fabrication.
  • Demonstrated potential for integrated fabrication of functional composite microstructures.