NanoOne 3D printer uses FAULHABER drives for alignment

UpNano’s NanoOne 3D printer uses two-photon lithography to produce micro- and nanoscale structures for applications such as microfluidics and medical research. Because printing accuracy depends on precise substrate alignment, the system uses three compact FAULHABER motors to position the substrate during fabrication.

The printed structures are not visible to the naked eye and require scanning electron microscopy for detailed observation. Some resemble small spheres with diameters of a fraction of a millimeter. Structural elements can be significantly thinner than a human hair. Applications include frameworks for cell growth, microfilters, microneedles and microlenses.

Development of high-resolution 3D printing

UpNano originated as a spin-off from the Vienna University of Technology, where its founders conducted research in high-resolution 3D printing. Demonstration objects have included detailed architectural models printed at micro scale. The commercial NanoOne system can produce structures smaller than 200 nanometers horizontally and smaller than 550 nanometers vertically.

Two-photon lithography relies on the interaction of two photons to initiate polymerization at a defined focal point. Because polymerization occurs only at this point, structures can be formed three-dimensionally rather than layer by layer.

Laser-based fabrication and applications

The laser system generates short, high-intensity pulses. The focused beam allows polymerization only at the targeted location, enabling complex geometries. The focal point can be moved through the material using precision optics.

Applications include microfluidic components, microlenses printed on glass fibers and structures added within existing microfluidic chips. An optional module enables printing with biomaterials that contain living cells. Polymerization occurs only at defined points, leaving surrounding cells intact. These constructs are used in pharmaceutical research as test systems.

Application areas and system specifications

The NanoOne system is used in fields including medical technology, pharmaceuticals and telecommunications. Reported applications include in-vitro fertilization and lenses for micro-endoscopes.

The printable size range extends from below 150 nanometers to over 40 millimeters. The system offers multiple lenses with different resolutions. Throughput can exceed 450 cubic millimeters per hour. Accurate substrate alignment is required to maintain printing precision. The substrate is mounted on a movable support.

FAULHABER drives in NanoOne systems

The support system, referred to as an automatic tilt correction insert, compensates for slight misalignment when inserting the substrate. Positioning is adjustable along three axes to achieve sub-micrometer flatness. Key components are mechanically decoupled from the housing to reduce external influences.

Movement of the support is driven by three precious metal commutated DC gearmotors with integrated encoders from FAULHABER’s 1512 … SR IE2-8 series. The motors have a diameter of 15 millimeters and a length of 14.3 millimeters. An optical encoder is integrated to support precise positioning. The gearmotors provide the torque required for alignment and contribute to consistent print accuracy.

For more information, visit faulhaber.com.