Researchers at the University of Strathclyde, a public research university in Glasgow, have developed a low-cost method to 3D print high-performance optical lenses for super-resolution microscopy, producing quality comparable to commercial glass for under £1 per lens. The breakthrough could make advanced imaging more accessible and enable fully customized optical systems for both research and industry.
“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,” said Dr. Jay Christopher, lead author.
Customised Imaging at the Nanoscale
The method combines 3D printing with silicone moulding and UV-curable resin to produce multi-element optical components with smooth surfaces that rival traditional glass lenses. Building on their previous work producing a fully 3D printed microscope, the team demonstrated that consumer-grade printers can deliver highly precise, affordable optical systems.
Using this technique, the researchers achieved resolutions of around 150 nanometres while imaging microtubules in a cell’s cytoskeleton—details typically beyond conventional optics. “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,” said Dr. Ralf Bauer, who led the research team.
The team compared their lenses against both high-end and budget commercial optics, finding similar performance. They plan to explore multi-focus and bio-inspired lens designs to expand the possibilities of 3D printed imaging systems.
“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,”added Dr. Christopher.
Expanding the Reach of 3D Printed Optics
Beyond microscopy, additive manufacturing is increasingly transforming optical design and fabrication across multiple fields. For instance, software company opdo has launched an AI-driven platform that rapidly generates manufacturable optical designs. Combined with volumetric 3D printing techniques like xolography, the platform enables components with micron-level precision and high transparency, streamlining the workflow from digital design to physical optical elements.
Similarly, researchers at the University of Stuttgart’s 4th Physics Institute demonstrated the use of 3D printed micro-optics in high-power laser systems. Using two-photon polymerization (2PP), they fabricated microscale lenses directly on optical fibers, integrating fibers and laser crystals into compact hybrid oscillators. The resulting systems delivered stable, high-output performance without damage to the printed optics.
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Featured image shows 3D Printed Lenses. Photo via University of Strathclyde.
