The recent collaborative review from researchers in Bangladesh and China dives into how light-based additive manufacturing is shaking up the world of photonics. Published in ChemPhysMater in 2025 under the title *Photonic systems in 3D printing*, the paper explores advanced fabrication techniques like stereolithography (SLA), digital light processing (DLP), and two-photon polymerization (TPP).
These methods are changing how we make optical and photonic components. They go way beyond traditional lithography in terms of versatility, precision, and customization.
Light-Assisted 3D Printing: A New Era for Photonics
Conventional lithographic processes stick to layered, flat designs. In contrast, light-assisted 3D printing lets us build complex, fully three-dimensional structures with tunable refractive properties.
This opens up possibilities for devices that once seemed out of reach due to tricky geometries or strict material limits.
The Shift from UV to Visible Light
The review highlights a major shift toward visible-light curing. This approach is safer and more biocompatible, making it possible to use fragile materials like hydrogels and even living cells.
By ditching potentially harmful UV exposure, researchers can better protect sensitive organic and polymer structures. That’s a big win for biomedical and life science applications.
Advanced Photocurable Materials and Photoinitiators
Success in photonic 3D printing depends on the combination of photocurable resins and high-performance photoinitiators. The review points out a few standouts:
- TPO – Cures fast and keeps yellowing to a minimum, which helps with optical clarity
- BAPO – Works efficiently under a wide range of light
- LAP – Biocompatible and great for hydrogel-based systems
These materials offer impressive transparency and structural precision. That’s key for applications like micro-optics and photonic crystals.
Techniques and Their Capabilities
SLA and DLP make it easy to quickly produce micro-optics and waveguides. They help bridge the gap between prototyping and mass production.
Meanwhile, femtosecond laser–driven TPP delivers nanoscale accuracy and enables the creation of detailed photonic crystals and integrated optical circuits.
Hybrid and Scalable Manufacturing Approaches
The paper points to new hybrid printing techniques as essential for scaling up micro-optical manufacturing. By combining different light-based methods, they manage to strike a balance between speed, precision, and functionality.
Applications in Diverse Fields
The reach of light-assisted additive manufacturing goes well beyond optics. Some highlighted areas include:
- Structural color materials – Imitating natural iridescence for displays and decoration
- Biomedical sensors – Sensitive devices that can pick up on biochemical changes
- Tunable optical devices – Adjustable for uses in telecommunications and imaging
- Terahertz metamaterials – Shaping electromagnetic waves for new sensing and communication tools
Overcoming Current Challenges
Progress has been impressive, but challenges stick around. Achieving both optical transparency and mechanical robustness remains tricky.
Manufacturers also feel pressure to boost production speed and expand material choices, all without letting quality slip.
Future Outlook: Intelligent Photonic Systems
The authors picture a future where multi-material printing, AI-driven optimization, and flexible optoelectronics all come together to create customizable, high-performance photonic systems.
These intelligent devices could adapt to their environments, unlocking fresh possibilities in everything from medical diagnostics to adaptive communication networks.
Here is the source article for this story: Researchers review photonic systems enabling next-generation 3D printed optics