A collaboration of German researchers presents the first instance of two-photon polymerisation induced by a mode-locked diode laser system, with a pulse length of 440 fs. Two-photon polymerisation allows for the production of complex microstructures, usually using an expensive laser system, such as Ti:sapphire. The development presented here works using a much cheaper diode laser, significantly reducing the cost of the process. Around the turn of the millennium, the research area of multiphoton polymerisation became well established; in particular, a technique known as direct laser writing (DLW) was developed to more easily produce photonic crystals with a range of uses, from thin-film optics to colour changing paints to photonic circuits. DLW requires a photoresist (a light sensitive material) to be illuminated by laser light of a frequency below its single-photon polymerisation threshold. When the laser light is tightly focused inside the photoresist, the light intensity may exceed the threshold for initiating multiphoton polymerisation. Authors Gordon Zyla (left) and Nils Surkamp (right) in their lab. SEM overview image of the ‘winding tower’ structure. Two-photon polymerisation manufacturing process.The oil immersion objective focusses the incident laser beam into the photoresist. Three-dimensional structuring can be obtained by moving the focal spot relative to the droplet. The smallest polymerisation is defined by the voxel size, which depends on the structuring speed and intensity of the focal spot. The SEM image in A. shows the fabricated lines structures between two cuboids. The SEM image in B. shows the ‘winding tower’ structure. In the past 10 years this area of research has seen a resurgence in interest, primarily due to the increased capabilities of diode lasers. One of the main drawbacks of multiphoton polymerisation is that it requires a high-frequency laser that can operate in the femtosecond range. Traditionally, appropriate laser systems of this type are expensive, such as Ti:sapphire lasers or fibre lasers. However, we are now starting to see diode lasers that can reliably operate in the femtosecond range for a fraction of the operating costs of conventional systems. Surkamp et al., in their work published in Electronics Letters, propose using a mode-locked diode laser, capable of producing ultrashort laser pulses 440 fs in length. In their design, the laser outputs an impressive 160 mW per pulse. The mode-locked nature of the laser is what allows pulses to reach the 440 fs pulse length. A key characteristic of two-photon polymerisation is that it has a high resolution, in the order of sub-100 nm. The resolution depends on the ‘voxel size’ – voxels being a 3D analogue of pixels. Therefore, with a small voxel size, very fine structures can be produced. The structures are produced layer-by-layer, in a manner similar to conventional 3D printing techniques. The size of the voxel is dependent on the structuring velocity (the speed at which the structure is produced) and the focus intensity. Surkamp et al. produced two structures, the first being two cuboids, 4 micrometres apart, connected by a number of lines. The lines were produced at increasing velocities to test how the technique's resolution would cope at different speeds. The second structure was much more complex, a winding ‘tower’ with additional embellishment in the structure. The tower has a roof, with two angled supports, and a central post containing a winding ‘staircase’ running up it. The two structures were analysed using a scanning electron microscope and look fantastic. The results clearly show the suitability of two-photon polymerisation as a way of producing structure at the micrometer scale. Diode lasers are much cheaper, meaning that the technique is accessible to a broader audience, not just those in well-funded laboratories. In addition, the work highlights the competitiveness of femtosecond optical pulse generation using diode lasers compared to fibre lasers – the current most compact femtosecond laser systems. With some additional tweaking, the technique could be used in the field of nanorobotics, where robots on the micro and sub-micro scale have the potential to be used in vivo. There are also obvious applications for producing ever smaller and more intricate circuitry components. Moreover, photonic integration concepts will further promote this development and promise to deliver ever more compact and cost-effective femtosecond diode laser systems in the coming decade.
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