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Free-space direct nanoscale 3D printing of metals and alloys enabled by two-photon decomposition and ultrafast optical trapping

Nature Materials (2024)Cite this article

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Abstract

Nanoscale three-dimensional (3D) printing of metals and alloys has faced challenges in speed, miniaturization and deficiency in material properties. Traditional nanomanufacturing relies on lithographic methods with material constraints, limited resolution and slow layer-by-layer processing. This work introduces polymer-free techniques using two-photon decomposition and optical force trapping for free-space direct 3D printing of metals, metal oxides and multimetallic alloys with resolutions beyond optical limits. This method involves the two-photon decomposition of metal atoms from precursors, rapid assembly into nanoclusters via optical forces and ultrafast laser sintering, yielding dense, smooth nanostructures. Enhanced near-field optical forces from laser-induced localized surface plasmon resonance facilitate nanocluster aggregation. Our approach eliminates the need for organic materials, layer-by-layer printing and complex post-processing. Printed Mo nanowires show an excellent mechanical performance, closely resembling the behaviour of single crystals, while Mo–Co–W alloy nanowires outperform Mo nanowires. This innovation promises the customizable 3D nanoprinting of high-quality metals and metal oxides, impacting nanoelectronics, nanorobotics and advanced chip manufacturing.

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Fig. 1: Process scheme, mechanism, simulation and demonstration of the 3D nanoprinting process and structures.
Fig. 2: Characterization of printed metals, alloy and metal oxides.
Fig. 3: Linear and curved 3D nanostructures.
Fig. 4: The in situ mechanical test of Co lattices, Mo nanowires and alloy nanowires.

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Data availability

The data that support the findings of this study are present in the paper and/or in the Supplementary Information. Additional data related to the paper are available from the corresponding author upon request.

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Acknowledgements

We thank L. Li from the Core Facility of Wuhan University for his assistance with TEM analysis; Y. Zhang from the Core Facility of Wuhan University for her assistance with focused ion beam testing; and engineer X. Ji for the support with the nanomechanical testing at the microscopic in situ mechanics laboratory at the Institute of Water Engineering Sciences at Wuhan University.

Author information

Author notes

  1. These authors contributed equally: Yaoyu Wang, Chenqi Yi, Wenxiang Tian.

Authors and Affiliations

  1. Institute of Technological Sciences, Wuhan University, Wuhan, China

    Yaoyu Wang, Chenqi Yi, Feng Liu & Gary J. Cheng

  2. State Key Laboratory of Water Resources Engineering and Management, Wuhan University & Changjiang Institute of Survey, Planning, Design and Research Corporation, Wuhan, P.R. China

    Wenxiang Tian

  3. Institute of Water Engineering Sciences, Wuhan University, Wuhan, China

    Wenxiang Tian

  4. School of Power and Mechanical Engineering, Wuhan University, Wuhan, China

    Feng Liu

  5. School of Industrial Engineering, Purdue University, West Lafayette, IN, USA

    Gary J. Cheng

  6. School of Materials Engineering, Purdue University, West Lafayette, IN, USA

    Gary J. Cheng

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  1. Yaoyu Wang
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Contributions

Y.W. and G.J.C. conceived this study. Y.W. carried out the experimental treatments, material characterization and data analysis. C.Y. carried out data analysis. W.T. carried out the in situ mechanical test. F.L. provided resources. Y.W. and G.J.C. wrote the draught of the paper. G.J.C. supervised the project. All authors discussed the results and commented on the paper. Y.W., C.Y. and W.T. contributed equally to this work.

Corresponding author

Correspondence to Gary J. Cheng.

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Peer review information

Nature Materials thanks Jianchao Ye and the other, anonymous, reviewer(s) for their contribution to the peer review of this work.

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Supplementary information

Supplementary Information

Supplementary Figs. 1–18 and Discussion.

Supplementary Video 1

Printing video of the spiral array.

Supplementary Video 2

Printing video of the diamond crystal structure.

Supplementary Video 3

Printing video of the triangular truss structure.

Supplementary Video 4

Printing video of the buckyball structure.

Supplementary Video 5

Printing video of the 3D flower structure.

Supplementary Video 6

Real-time video of the compression test on the 3D lattice structure.

Supplementary Video 7

Real-time video of the in situ compression of a Mo nanowire.

Supplementary Video 8

Real-time video of in situ tension of a Mo nanowire.

Supplementary Video 9

Real-time video of in situ tension of an alloy nanowire.

Supplementary Video 10

Printing videos with different irradiation times at single points.

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Wang, Y., Yi, C., Tian, W. et al. Free-space direct nanoscale 3D printing of metals and alloys enabled by two-photon decomposition and ultrafast optical trapping. Nat. Mater. (2024). https://doi.org/10.1038/s41563-024-01984-z

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