Key Takeaways
- UpNano’s new 3D Adaptive Resolution (3DAR) adds voxel‑level shape control to its existing two‑photon polymerisation (2PP) platform.
- 3DAR uses grayscale lithography to vary voxel dimensions on‑the‑fly, delivering smoother surfaces without sacrificing build speed.
- The technology maintains 100 nm lateral resolution while allowing layer thicknesses up to 10 µm, a ten‑fold increase over conventional 2PP layer heights.
- A $7 M Series A round (2024) will fund hardware upgrades, software integration, and scaling to medium‑volume production.
- Compared with traditional 2PP, 3DAR offers up to 30 % faster build times for complex geometries while preserving sub‑micron accuracy.
UpNano Introduces 3D Adaptive Resolution (3DAR)
Background: UpNano’s 2PP Heritage
UpNano, an Austrian startup specializing in nanoscale additive manufacturing, has built a reputation on two‑photon polymerisation (2PP) printers capable of 100 nm feature resolution across volumes ranging from sub‑micron to centimetre‑scale parts. The platform has already attracted $7 million in venture funding (2024) to accelerate iterative hardware improvements and expand production capacity.
What Is 3DAR?
The latest breakthrough, dubbed 3D Adaptive Resolution (3DAR), augments the 2PP core with grayscale lithography. Instead of a fixed voxel size, the system can modulate the intensity profile of each laser pulse, shaping individual voxels in three dimensions during the print run.
- Voxel‑by‑voxel geometry control: Each voxel can be elongated, flattened, or tapered to match the local surface curvature.
- Dynamic layer thickness: Builders can retain thick layers (up to 10 µm) for bulk regions while automatically switching to thin layers (≈0.5 µm) for fine details.
- Laser focus optimisation: By tailoring voxel size, the laser’s focal spot stays at the optimal numerical aperture, preserving sub‑micron precision even at higher speeds.
The net effect is a smoother surface finish—often comparable to a high‑triangle‑count mesh in CAD—without the need for post‑process polishing.
How 3DAR Improves Speed and Accuracy
Traditional 2PP printers operate with a single voxel geometry throughout a build, forcing a trade‑off:
| Parameter | Conventional 2PP | 3DAR (UpNano) |
|---|---|---|
| Minimum voxel size | 100 nm × 100 nm × 500 nm | 100 nm × 100 nm × 500 nm (adaptive) |
| Typical layer thickness | 1 µm (fixed) | 0.5 µm – 10 µm (dynamic) |
| Build speed (complex part) | Baseline | +30 % on average |
| Surface roughness (Ra) | 0.8 µm | 0.4 µm (≈50 % reduction) |
| Material waste | 12 % | 9 % (due to finer voxel placement) |
By keeping thicker layers where geometry permits and only refining where necessary, 3DAR cuts overall print time while still delivering nanometer‑scale dimensional fidelity.
Real‑World Applications
- Medical implants: Micro‑textured surfaces for osseointegration can be printed in a single run, eliminating secondary machining.
- Micro‑optics: Free‑form lenses with graded curvature benefit from voxel‑shaped exposure, achieving optical tolerances < λ/10.
- Aerospace micro‑structures: Lattice‑filled brackets and heat‑sink fins can be produced at centimetre scale while preserving internal channels as small as 150 nm.
Funding and Roadmap
The $7 M Series A secured in early 2024 will be allocated as follows:
| Allocation | Percentage |
|---|---|
| Hardware R&D (laser, optics) | 45 % |
| Software stack (adaptive slicing, AI‑driven voxel planning) | 30 % |
| Production scaling (clean‑room expansion) | 15 % |
| Market development & certification | 10 % |
UpNano aims to ship its first 3DAR‑enabled production units by Q2 2025 and to certify the process for ISO/ASTM 52900 compliance by the end of 2025.
Bottom Line
UpNano’s 3D Adaptive Resolution bridges the long‑standing gap between nanometer‑level precision and reasonable build throughput. By granting voxel‑by‑voxel shape control through grayscale lithography, the company delivers smoother parts, reduces material waste, and accelerates production by roughly a third—all while retaining its hallmark 100 nm resolution. The recent $7 M funding round positions UpNano to transition from prototyping to medium‑volume manufacturing, making 3DAR a compelling option for industries that demand both extreme detail and speed.
