Fast micron-scale 3D printing with a resonant-scanning two-photon microscope

Abstract

3D printing allows rapid fabrication of complex objects from digital designs. One 3D-printing process, direct laser writing, polymerises a light-sensitive material by steering a focused laser beam through the shape of the object to be created. The highest-resolution direct laser writing systems use a femtosecond laser, steered using mechanised stages or galvanometer-controlled mirrors, to effect two-photon polymerisation. Here we report a new high-resolution direct laser writing system that employs a resonant mirror scanner to achieve a significant increase in printing speed over current methods while maintaining resolution on the order of a micron. This printer is based on a software modification to a commercially available resonant-scanning two-photon microscope. We demonstrate the complete process chain from hardware configuration and control software to the printing of objects of approximately 400 × 400 × 350 μm, and validate performance with objective benchmarks. Released under an open-source license, this work makes micron-scale 3D printing available at little or no cost to the large community of two-photon microscope users, and paves the way toward widespread availability of precision-printed devices.