Holographic tomographic volumetric additive manufacturing

Maria Isabel Álvarez-Castaño (), Andreas Gejl Madsen, Jorge Madrid-Wolff, Viola Sgarminato, Antoine Boniface, Jesper Glückstad and Christophe Moser ()
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Maria Isabel Álvarez-Castaño: Ecole Polytechnique Fédérale de Lausanne
Andreas Gejl Madsen: University of Southern Denmark
Jorge Madrid-Wolff: Ecole Polytechnique Fédérale de Lausanne
Viola Sgarminato: Ecole Polytechnique Fédérale de Lausanne
Antoine Boniface: Ecole Polytechnique Fédérale de Lausanne
Jesper Glückstad: University of Southern Denmark
Christophe Moser: Ecole Polytechnique Fédérale de Lausanne

Nature Communications, 2025, vol. 16, issue 1, 1-15

Abstract: Abstract Several 3D light-based printing technologies have been developed that rely on the photopolymerization of liquid resins. A recent method, so-called Tomographic Volumetric Additive Manufacturing, allows the fabrication of microscale objects within tens of seconds without the need for support structures. This method works by projecting intensity patterns, computed via a reverse tomography algorithm, into a photocurable resin from different angles to produce a desired 3D shape when the resin reaches the polymerization threshold. Printing using incoherent light patterning has been previously demonstrated. In this work, we show that a light engine with holographic phase modulation unlocks new potential for volumetric printing. The light projection efficiency is improved by at least a factor 20 over amplitude coding with diffraction-limited resolution and its flexibility allows precise light control across the entire printing volume. We show that computer-generated holograms implemented with tiled holograms and point-spread-function shaping mitigates the speckle noise which enables the fabrication of millimetric 3D objects exhibiting negative features of 31 μm in less than a minute with a 40 mW light source in acrylates and scattering materials, such as soft cell-laden hydrogels, with a concentration of 0.5 million cells per mL.

Date: 2025
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DOI: 10.1038/s41467-025-56852-4

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