This paper presents a comprehensive review of recent advances in micro-additive manufacturing enabled by novel optical methods with an emphasis on photopolymerization-based printing processes. Additive manufacturing, also known as three-dimensional (3D) printing, has become an important engineering solution to construct customized components or functional devices at low cost. As a green manufacturing technology, 3D printing has the advantages of high energy efficiency, low material consumption, and high precision. The rapid advancement of 3D printing technology has broadened its applications from laboratory research to industrial manufacturing. Generally, 3D objects to be printed are constructed digitally [e.g., via computer-aided design (CAD) programs] by connecting a 3D dot array, where a dot is defined as a voxel through mechanical, electrical, or optical means. The voxel size ranges from a few orders of magnitude of the wavelength of light to the sub-diffraction limit, achieved by material nonlinearity and precise power thresholding. In recent years, extensive research in optical additive manufacturing has led to various breakthroughs in quality, rate, and reproducibility. In this paper, we review various micro-3D printing techniques, including single-photon and two-photon processes, with a focus on innovative optical methods, e.g., ultrafast beam shaping, digital holography, and temporal focusing. We also review and compare recent technological advances in serial and parallel scanning systems from the perspectives of resolution, rate, and repeatability, where the strengths and weaknesses of different methods are discussed for both fundamental and industrial applications.
In this Letter, we present a new, to our knowledge, aberration-free 3D imaging technique based on digital micromirror device (DMD)-based two-photon microscopy and sensorless adaptive optics (AO), where 3D random-access scanning and modal wavefront correction are realized using a single DMD chip at 22.7 kHz. Specifically, the DMD is simultaneously used as a deformable mirror to modulate a distorted wavefront and a fast scanner to maneuver the laser focus in a 3D space by designed binary holograms. As such, aberration-free 3D imaging is realized by superposing the wavefront correction and 3D scanning holograms. Compared with conventional AO devices and methods, the DMD system can apply optimal wavefront correction information to different imaging regions or even individual pixels without compromising the scanning speed and device resolution. In the experiments, we first focus the laser through a diffuser and apply sensorless AO to retrieve a corrected focus. After that, the DMD performs 3D scanning on a Drosophila brain labeled with green fluorescent protein. The two-photon imaging results, where optimal wavefront correction information is applied to
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separate regions, demonstrate significantly improved resolution and image quality. The new DMD-based imaging solution presents a compact, low-cost, and effective solution for aberration-free two-photon deep tissue imaging, which may find important applications in the field of biophotonics.
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