Comparative study of Two-Photon Polymerization and Micro-Stereolithography Printing Performance

Abstract

This study explores the dimensional precision and reproducibility of Two-Photon Polymerization (2PP) in microscale additive manufacturing, using the NanoOne 1000 system and UpPhoto resin. The research focuses on identifying and minimizing common fabrication issues such as shrinkage, erosion, ellipticity, and edge distortion, phenomena often encountered in both 2PP and Micro Stereolithography (µSLA). By adapting parameter tuning strategies commonly used in µSLA, the study demonstrates how targeted adjustments to process settings—such as laser power, line spacing, and voxel compensation—can significantly improve output consistency in 2PP. A series of nine design versions were tested, culminating in a final configuration (version 9) that combined geometry pre-compensation and increased block height to mitigate stitching artifacts and shape distortions. The optimized setup produced over 100 parts with dimensional deviations consistently within ±2 µm of the design target. Statistical metrics (Cp and Cpk) confirmed a high level of process control. These results directly address the outdated perception of 2PP as slow or unreliable. Instead, the findings highlight how advancements in hardware, materials, and software have positioned 2PP as a scalable, high-resolution technique for rapid, repeatable microfabrication.

Date of Award	2025
Original language	English
Supervisor	Jaroslaw Jacak (Supervisor)