UpNano develops new 3D printing process for high-precision quartz glass objects

UpNano GmbH from Vienna has developed a new manufacturing process for 3D-printed objects made of quartz glass in collaboration with Glassomer GmbH from Freiburg. This technology enables the production of high-precision components in the millimetre and centimetre range and is based on two-photon polymerization (2PP), which is carried out using UpNano’s NanoOne printers. These printers are currently the fastest commercially available 2PP 3D printers.

The production of complex and small objects from fused silica, a material with a high melting point, is particularly challenging. Until now, the available methods were limited to non-commercially available devices, which often produced rough surfaces. However, the new process from UpNano and Glassomer enables the production of smooth quartz glass components with structures down to the micrometer range.

“It’s a three-step process,” explains Markus Lunzer, Team Leader of Materials & Application at UpNano. “The first step is to design and print the desired structure, taking advantage of all the benefits of 2PP 3D printing. The second step is to remove the organic binder material, followed by a high-temperature sintering process, the third step.”

The core of the process is a newly developed nanocomposite called “UpQuartz”, which contains SiO₂ nanoparticles and a special polymer matrix that enables 2PP printing. After printing, a “green part” is created that has the final shape. By heating to 600 °C, the polymer matrix is removed and the remaining “brown part” is sintered at 1300 °C, whereby an isotropic shrinkage of around 30 % occurs. This can be compensated for by making appropriate adjustments to the printing process.

“This innovative production process developed by us,” says Markus Lunzer, ”is ideal for larger 3D-printed glass parts that require high resolution and precision in the fields of mechanical engineering, chemistry, medicine or research.”

This development represents a significant advance in 2PP 3D printing technology and complements UpNano’s previous successes, such as the production of microfluidic chips and microstructures made of tungsten and platinum with sub-micrometer resolution. UpNano has also recently completed a software update that enables seamless stitching and further enhances the versatility of the NanoOne printers.

“The speed, resolution and versatility of our printers make them powerful tools for the mass production of high-precision parts. Our constantly growing range of materials expands the spectrum of applications. In due course, we will also soon be expanding our range of services,” adds Bernhard Küenburg, Managing Director of UpNano.

UpNano’s turnover increased by 57% in 2023 and the NanoOne printers are now in use on five continents, underlining the company’s success and innovative strength.