Large volume nanoscale 3D printing: Nano-3DP

Abstract 3D printers suffer from the inverse relationship between throughput and minimum feature size; with smaller features inducing a cubic increase in print time. Here we introduce Nano-3DP, a hybrid process that combines digital light projection 3D printing with nanoscale-relief patterning. The tool enables large volume (cm3) prints with nanoscale details at a truly rapid rate (~120 mm/hour). 40 nm features, half the size of the finest printed details to date, are produced across a scalable print volume. We address the intrinsic issues of throughput and pixel induced surface inhomogeneity. To demonstrate the unique potential realized by this printing method across different areas of science optical lenses, injection molding tools and bio-implants originally acquired by x-ray CT are produced with functional nanoscale surface details. Notably, in vitro bone cell analysis delivered a profound 4.5-fold increase in osteogenesis purely through the inclusion of nanoscale features on the printed surfaces.