2PP laser prototyping of porous non-wovens from digital models

Overview

2PP Laser Prototyping presents an innovative approach to creating high-fidelity porous non-woven prototypes using Two-Photon Polymerization (2PP) direct laser writing. This technology allows the fabrication of complex structures directly from digital CAD models, with precise voxel-by-voxel control. The process produces prototypes with fiber diameters of approximately 25 µm and pore sizes ranging from 50 to 500 µm, meeting stringent requirements such as ≤5% deviation in pore volume. This approach is particularly beneficial for industries requiring custom non-woven structures, as it circumvents traditional manufacturing limitations.

Technical specifications

The core of this solution is a femtosecond laser that enables the voxel-by-voxel fabrication, ensuring high precision at a ~5 µm resolution. The system can create a non-woven layer of 1.5 cm x 1.5 cm x 0.5 cm. With custom photopolymers, users can tailor mechanical flexibility and fluid-handling properties. The technology has been structured into a phased roadmap: Phase 1 focuses on initial fabrication and validation, Phase 2 extends performance through multi-layer structures, and Phase 3 optimizes the digital-to-physical workflow and scales up the process.

Technology readiness level

Currently at TRL 4, this technology has demonstrated lab-scale validation and is moving towards further development phases. It has proven effective in similar high-resolution applications, with the potential for extending capabilities through multi-beam 2PP or hybrid techniques. The project aims to deliver a comprehensive roadmap for scale-up and broader application in collaboration with partners like P&G.