Bridging dimensions: combining one- and two-photon 3D printing for microfluidic device fabrication
Oliver Walker1,2, Robin R Benedix2, Julian Fischer2
1Institute of Biomaterials and Biomolecular Systems, University of Stuttgart, Stuttgart, Germany. michael.heymann@bio.uni-stuttgart.de.
Lab on a Chip
|July 6, 2026
Summary
This study introduces a faster 3D microfluidic fabrication method by combining two-photon and one-photon printing. This hybrid approach significantly reduces production time while maintaining high accuracy for creating uniform GelMA-based foams.
Area of Science:
- Biomedical Engineering
- Materials Science
- Additive Manufacturing
Background:
- Additive manufacturing enables complex 3D microfluidic device fabrication.
- Integrating multiple printing techniques presents challenges in alignment and interface design.
Purpose of the Study:
- To develop a hybrid 3D printing workflow for microfluidics that enhances fabrication speed without sacrificing precision.
- To achieve reproducible assembly and fluidic sealing between different printing modalities.
Main Methods:
- Combined high-resolution two-photon printing with fast one-photon printing for microfluidic features.
- Implemented specific alignment strategies and interface design tolerances for seamless integration.
- Utilized GelMA-based materials for foam production.
Main Results:
- Reduced overall fabrication time by approximately 20-fold.
- Achieved highly monodisperse GelMA-based foams with a polydispersity index below 5%.
- Produced tunable bubble radii ranging from 235 to 400 μm.
Conclusions:
- Hybrid multi-modal 3D printing offers significant efficiency gains in microfluidic fabrication.
- Precision is strategically applied only where critical, optimizing the workflow.
- This approach enables the creation of advanced microfluidic devices with controlled material properties.
