Scientists have demonstrated a new method for producing high-quality optical lenses for super-resolution microscopy using consumer-grade 3D printers – costing less than £1 each to make.
The breakthrough, led by researchers at the University of Strathclyde, combines 3D printing, silicone moulding and UV-curable resin to create multi-element optical components that deliver performance comparable to commercial glass lenses.
The research builds on earlier work where the team produced a fully 3D-printed microscope using the same type of printers.
The new approach could make advanced imaging tools more accessible and enable fully customised optical systems for research and industry.
Customised imaging
Dr Jay Christopher, lead author from Strathclyde, said: “We created optical parts that enable imaging of life’s smallest building blocks at a remarkable level of detail. This approach opens the possibility for customised imaging systems and unlocks scenarios that are traditionally either impossible or require costly glass manufacturing services.”
The team used their technique to achieve a resolution of around 150 nanometres when imaging microtubules in a cell’s cytoskeleton. This level of detail is typically beyond the reach of conventional optical systems.
Dr Christopher added: “Our new approach could empower scientists and companies to access tools previously locked behind specialist technology with high costs. Using budget-friendly 3D printers and materials, they could manufacture their own components to solve problems they are facing and, in turn, generate unique research and product development solutions.”
For this latest advancement, they developed a method to reduce optical scattering caused by the layer-by-layer printing process, which can lead to unwanted diffraction effects. By creating a silicone mould and casting the lens in UV-curable resin, they achieved surfaces smooth enough to rival commercial optics.
New designs
Dr Ralf Bauer, who led the research team, said: “With consumer-grade 3D printing technologies becoming more sophisticated and precise every year, our ambitions grew from seeing whether 3D-printed lenses could be used for biological imaging to exploring how far they could go within the latest advanced imaging concepts.”
The researchers compared their low-cost optics against high-end and budget commercial lenses, finding that their printed lenses performed to a similar standard. They now plan to explore new designs, including multi-focus points in three dimensions and bio-inspired imaging systems.
The study is published in Biomedical Optics Express, part of the Optica Publishing Group.