3D printing as a key technology for photonic systems at the Ferdinand Braun Institute

The Berlin-based Ferdinand Braun Institute is demonstrating at Photonics West 2026 in San Francisco how additive manufacturing is becoming increasingly established in photonic systems engineering. In addition to semiconductor lasers and optical modules, particular attention is being paid to the 3D printing of functional ceramic structures, which open up new degrees of freedom in miniaturization and integration.

A central exhibit is an optical frequency reference whose supporting structure has been manufactured entirely additively from aluminum oxide. The 3D-printed ceramic substrates serve not only as mechanical mounts but also enable highly precise alignment of all optical components directly within the print design. The resulting system achieves a volume of only a few milliliters, combined with very low mass and high mechanical stability. According to the institute, the achieved spectral stability meets the requirements of quantum sensors based on cold atoms and is therefore suitable for use outside classical laboratory environments.

The use of additive manufacturing addresses specific technical challenges. Ceramic 3D-printing processes allow for complex geometries, integrated alignment structures, and defined thermal properties that would be difficult to realize with conventional manufacturing methods. Especially in optical and atomic-physics systems, reduced thermal drift and high resistance to vibration have a direct impact on measurement accuracy. The FBH sees this as an important building block for robust quantum technologies, for example in mobile sensors or space-qualified instruments.

At the same time, the institute is demonstrating the industrial use of high-performance diode laser systems in metal-based 3D printing. Direct diode lasers with wavelengths matched to the absorption behavior of specific metals have been successfully tested in manufacturing processes. The combination of efficient laser sources and additively manufactured structural components illustrates how photonic technologies and 3D printing can mutually reinforce one another.

Overall, it is clear that additive manufacturing at the FBH is not viewed as an isolated technology, but as an integral part of modern photonic systems. This enables the creation of compact, robust, and precise solutions that facilitate the transfer from research into demanding applications.