Direct Laser 3D Nanoprinting of Metals and Their Alloys

nnovative manufacturing technologies like direct laser 3D nanoprinting are opening up entirely new possibilities—especially in fields such as nanoelectronics, metamaterials, and biomedical microtechnology. At cross-ING, we follow such technological advances closely to provide our clients with the most effective solutions for complex engineering challenges. This article highlights one such exciting development.

What is Direct Laser 3D Nanoprinting?

Direct laser 3D nanoprinting has emerged as a groundbreaking approach in high-resolution additive manufacturing, offering the potential to produce complex three-dimensional (3D) metallic geometries with nanoscale precision.

Alain Reiser highlights recent significant advancements in this field [1], focusing on a method introduced by Wang and colleagues. Their approach addresses long-standing challenges in nanoscale additive manufacturing of metals by enabling direct laser writing of metals and alloys without the need for thermal post-processing.

Metallic 3D Nanoprinting Without Post-Processing

Traditional techniques—such as direct laser writing using two-photon polymerization (2PP-DLW)—have played an important role in creating polymer-based 3D geometries. However, extending these capabilities to metals has been hindered by limitations such as high-temperature requirements and resulting material shrinkage. These challenges are particularly problematic for thermally sensitive substrates, making conventional methods incompatible with certain applications.

Wang’s method circumvents these issues with a polymer-free approach using two-photon decomposition (TPD). This innovative technique allows laser-induced synthesis and nanoparticle consolidation to occur simultaneously, enabling the creation of dense metallic structures at room temperature.

The process involves two-photon absorption in a precursor solution containing carbonyl metal complexes. This triggers decomposition into metal clusters, which are then sintered by localized laser heating to form high-density structures. The technique offers several advantages, including nanoscale resolution (up to 100 nm), the ability to produce intricate geometries, and compatibility with a wide range of metals and alloys. Furthermore, alloying can be achieved by mixing different precursors, as demonstrated with molybdenum–cobalt–tungsten structures.

Figure 1. 3D laser writing enables complex geometries with high reliability and resolution [2].

Challenges and Outlook

Despite these advances, challenges remain. Throughput is still a significant limitation, as current writing speeds only allow deposition in the micrometer-per-second range—falling behind the high-speed capabilities of established 2PP-DLW methods.

Additionally, while the fabricated structures exhibit impressive compressive strength comparable to single-crystal nanopillars, their elastic modulus remains below bulk values, indicating further need for material property optimization.

Applications and Future Potential

The impact of this technology is immense. By introducing 3D nanofabrication capabilities for inorganic materials, this approach paves the way for advances in nanoelectronics, nanorobotics, metamaterials, and micro-scale biomedical devices. With continued improvements in print speed and material performance, the potential to transform applications in these areas is substantial.

The innovation presented by Wang and colleagues marks a major milestone in the evolution of 3D nanomanufacturing, laying the foundation for a new era of high-performance nanoscale devices and materials.

How Can cross-ING Support You?

Emerging technologies like direct laser 3D nanoprinting show how rapidly manufacturing methods are evolving. At cross-ING, we leverage this knowledge to develop innovative solutions for complex engineering challenges—particularly in the areas of additive manufacturing design, materials science, and engineering consulting.

Get in touch with us to learn how we can drive your projects forward with cutting-edge technologies.

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References:

[1] Reiser, A. (2024). Direct Laser 3D Nanoprinting of Metals and Alloys. Nature Materials, 1–2.[2] Wang, Y., Yi, C., Tian, W., Liu, F., & Cheng, G. J. (2024). Direct Free-Space Nanoscale 3D Printing of Metals and Alloys via Two-Photon Decomposition and Ultrafast Optical Trapping. Nature Materials, 1–9.