Free-space direct nanoscale 3D printing of metals and alloys enabled by two-photon decomposition and ultrafast optical trapping.

Nanoscale three-dimensional (3D) printing of metals and alloys has faced challenges in speed, miniaturization and deficiency in material properties. Traditional nanomanufacturing relies on lithographic methods with material constraints, limited resolution and slow layer-by-layer processing. This work introduces polymer-free techniques using two-photon decomposition and optical force trapping for free-space direct 3D printing of metals, metal oxides and multimetallic alloys with resolutions beyond optical limits. This method involves the two-photon decomposition of metal atoms from precursors, rapid assembly into nanoclusters via optical forces and ultrafast laser sintering, yielding dense, smooth nanostructures. Enhanced near-field optical forces from laser-induced localized surface plasmon resonance facilitate nanocluster aggregation. Our approach eliminates the need for organic materials, layer-by-layer printing and complex post-processing. Printed Mo nanowires show an excellent mechanical performance, closely resembling the behaviour of single crystals, while Mo-Co-W alloy nanowires outperform Mo nanowires. This innovation promises the customizable 3D nanoprinting of high-quality metals and metal oxides, impacting nanoelectronics, nanorobotics and advanced chip manufacturing.

Single-Cell Synchro-Subtractive-Additive Nanoscale Surgery with Femtosecond Lasers.

Herein, an in situ "synchro-subtractive-additive" technique of femtosecond laser single-cell surgery (FLSS) is presented to address the inadequacies of existing surgical methods for single-cell manipulation. This process is enabled by synchronized nanoscale three-dimensional (3D) subtractive and additive manufacturing with ultrahigh precision on various parts of the cells, in that the precise removal and modification of a single-cell structure are realized by nonthermal ablation, with synchronously ultrafast solidification of the specially designed hydrogel by two photopolymerizations. FLSS is a minimally invasive technique with a post-operative survival rate of 70% and stable proliferation. It opens avenues for bottom-up synthetic biology, offering new methods for artificially synthesizing organelle-like 3D structures and modifying the physiological activities of cells.

Optical force brush enabled free-space painting of 4D functional structures.

Femtosecond laser-based technique called two-photon polymerization (TPP) has emerged as a powerful tool for nanofabrication and integrating nanomaterials. However, challenges persist in existing three-dimensional (3D) nanoprinting methods, such as slow layer-by-layer printing and limited material options due to laser-matter interactions. Here, we present an approach to 3D nanoprinting called free-space nanopainting, using an optical force brush (OFB). OFB enables precise spatial writing paths, instantaneous adjustment of linewidths and concentrations, and unrestricted resolution beyond optical limits. OFB allows rapid aggregation and solidification of radicals, resulting in narrower lines at lower polymerization thresholds and enhanced sensitivity to laser energy. This advancement enables high-accuracy free-space painting, analogous to Chinese brush painting on paper. The printing speed is increased substantially compared to layer-by-layer methods, from 100 to 1000 times faster. We successfully printed various bionic muscle models derived from 4D nanostructures with tunable mechanical properties, responsive to electrical signals, and excellent biocompatibility.