Selective Laser-Induced Etching of 3D Precision Quartz Glass Components for Microfluidic Applications—Up-Scaling of Complexity and Speed

TLDR

Precise 3‑D structures in quartz glass have been produced for over a decade by combining ultrafast laser modification with selective laser‑induced etching. The authors investigate how to extend this technique to enable faster, more complex fabrication. The SLE process employs a three‑axis sample stage and a fast 3‑D laser‑focus system, and by optimizing pulse duration, increasing writing speed, and integrating a CAD‑compatible printer driver, it now produces complex, high‑precision quartz glass structures rapidly and at scale. The study found that longer pulse durations improve selectivity, higher writing speeds increase precision, and the integrated CAD‑compatible printer driver enables automated, mass‑produced complex quartz glass microfluidic components.

Abstract

By modification of glasses with ultrafast laser radiation and subsequent wet-chemical etching (here named SLE = selective laser-induced etching), precise 3D structures have been produced, especially in quartz glass (fused silica), for more than a decade. By the combination of a three-axis system to move the glass sample and a fast 3D system to move the laser focus, the SLE process is now suitable to produce more complex structures in a shorter time. Here we present investigations which enabled the new possibilities. We started with investigations of the optimum laser parameters to enable high selective laser-induced etching: surprisingly, not the shortest pulse duration is best suited for the SLE process. Secondly we investigated the scaling of the writing velocity: a faster writing speed results in higher selectivity and thus higher precision of the resulting structures, so the SLE process is now even suitable for the mass production of 3D structures. Finally we programmed a printer driver for commercial CAD software enabling the automated production of complex 3D glass parts as new examples for lab-on-a-chip applications such as nested nozzles, connectors and a cell-sorting structure.