MIT’s Lincoln Laboratory has introduced an additive manufacturing process that enables the production of complex glass components at comparatively low temperatures. Unlike traditional glassmaking techniques that require temperatures exceeding 1,000 °C, the new method relies on a heat treatment step at just 250 °C. This not only reduces energy consumption but also allows integration with temperature-sensitive materials.
At the core of the process is a technique known as Direct Ink Writing (DIW), in which a specially formulated ink is extruded layer by layer. This ink consists of a silicate solution combined with inorganic nanoparticles that can be tailored to influence specific optical, chemical, or electrical properties depending on their composition. The printing is done at room temperature. The printed object is then cured in a mineral oil bath heated to 250 °C, resulting in a stable glass composite structure. A final cleaning step in an organic solvent removes residual components, leaving behind a purely inorganic end product.
This method enables the fabrication of items such as freeform lenses, microfluidic components, or heat-resistant electronic housings—applications that were previously limited by geometric constraints or high processing costs. Tests show that the resulting glass structures exhibit high dimensional accuracy, thermal stability, and minimal shrinkage.
Current research efforts focus on improving optical transparency and developing new ink formulations to enable a wider range of functional properties. In the long term, this technique could open up new applications in optics, sensing, and microfluidics—fields where conventional glass technologies have faced technical limitations.
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