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Ultrafast Laser-Enabled 3D Glass Microchannel Reactors.

Xiaolong Li^1,2, Jinxin Huang^1,2, Jian Xu^1,2

¹Engineering Research Center for Nanophotonics and Advanced Instrument, School of Physics and Electronic Science, East China Normal University, Shanghai 200241, China.

Sensors (Basel, Switzerland)

|December 11, 2025

Summary

Ultrafast laser technology enables the flexible fabrication of 3D glass microchannel reactors. These advanced reactors offer superior performance for continuous-flow synthesis in chemical engineering and pharmaceutical production.

Keywords:

3D microstructures continuous-flow synthesis glass microchannel reactors online monitoring ultrafast laser-assisted etching

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Area of Science:

Chemical Engineering
Materials Science
Microfluidics

Background:

Conventional microchannel reactors are limited to 2D planar geometries.
Producing 3D architectures for enhanced microchemical performance is challenging.
Ultrafast laser microfabrication offers a solution for creating complex 3D structures.

Purpose of the Study:

To review fabrication techniques for 3D glass microchannel reactors using ultrafast lasers.
To highlight advancements in large-scale and high-precision manufacturing.
To introduce applications in continuous-flow microchemical reactions.

Main Methods:

Utilizing nonlinear optical effects of ultrafast lasers.
Employing direct material removal or subsequent chemical etching.
Fabricating hollow microchannel structures within glass materials.

Main Results:

Flexible creation of 3D hollow microchannel structures in glass.
Advancements in large-scale, high-precision all-glass microchannel manufacturing.
Facile integration of online monitoring modules for enhanced functionality.

Conclusions:

Ultrafast laser-enabled 3D glass microchannel reactors provide superior microchemical performance.
These reactors hold significant potential for innovative industrial-scale continuous-flow manufacturing.
Applications span chemical engineering and pharmaceutical production.