Single-photon-assisted two-photon polymerization

Light-based additive manufacturing (AM) has revolutionized the fabrication of complex three-dimensional (3D) objects offering a cost-effective and high-speed alternative to traditional machining. One-photon polymerization is a key process in this advancement, standing out for rapid printing time, albeit with limited resolution. Two-photon polymerization (2PP) empowers AM with unprecedented resolution but is accompanied by a tradeoff of prolonged printing times. We propose combining the single-photon absorption (1PA) and 2PP to benefit from the dual capabilities, allowing for faster printing while maintaining high resolution and improved depth sectioning, respectively. In this study, we employ a blue light source to pre-excite a photocurable resin by 1PA followed by a precisely focused femtosecond (fs) beam to provide the missing energy necessary to reach the polymerization threshold to solidify the resin through two-photon absorption. First, we investigate the impact of pre-sensitization by blue light illumination on 2PP and demonstrate one order of magnitude faster printing time for a voxel size of 150 nm as compared to the same voxel size printed by 2PP only. Then, we build a custom 2PP printer utilizing blue light sensitization in a light-sheet mode and demonstrate successful 3D prints.