<p>The integration of functional nanomaterials into 3D printed photonic devices remains a key challenge in additive manufacturing due to nanoparticle aggregation and poor compatibility with photopolymers. In this study, we present a scalable and efficient 3D printing-assisted in-situ approach for embedding gold nanoparticles (Au-NPs) into hydrogel-based Fresnel lenses fabricated from a hydroxyethyl methacrylate (HEMA)-based resin and masked stereolithography (MSLA)-enabled vat photopolymerization. The 3D printing process not only defines the structural precision of the lens but also contributes chemically to nanoparticle synthesis, as residual vinyl groups and functional moieties in the printed polymer network enable the thermal reduction of gold precursors without the need for external reducing agents. This post-printing thermal immersion results in a uniform distribution of plasmonic Au-NPs throughout the polymer matrix, preserving optical clarity and design fidelity. Structural, morphological, and spectroscopic analyses confirm the successful formation of plasmonic nanocomposites, exhibiting distinct localized surface plasmon resonance (LSPR) features in the 540–560&#xa0;nm range. The plasmonic Fresnel lenses demonstrate tunable optical absorption, angle-dependent polarization sensitivity, and chromatic focusing behavior. Focal length measurements show minimal deviation from the designed geometry, while polarization studies reveal enhanced directionality and spectral modulation due to embedded nanoparticles. These findings highlight the synergy between additive manufacturing and in-situ nanomaterial synthesis, offering a promising route to multifunctional, nanostructured optical components for filtering, communication, sensing, and ophthalmic photonics applications.</p>

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3D printing-assisted in-situ integration of gold nanoparticles into optical lenses for functional photonic applications

  • Murad Ali,
  • Said El Turk,
  • Fahad Alam,
  • Rashid K. Abu Al-Rub,
  • Haider Butt

摘要

The integration of functional nanomaterials into 3D printed photonic devices remains a key challenge in additive manufacturing due to nanoparticle aggregation and poor compatibility with photopolymers. In this study, we present a scalable and efficient 3D printing-assisted in-situ approach for embedding gold nanoparticles (Au-NPs) into hydrogel-based Fresnel lenses fabricated from a hydroxyethyl methacrylate (HEMA)-based resin and masked stereolithography (MSLA)-enabled vat photopolymerization. The 3D printing process not only defines the structural precision of the lens but also contributes chemically to nanoparticle synthesis, as residual vinyl groups and functional moieties in the printed polymer network enable the thermal reduction of gold precursors without the need for external reducing agents. This post-printing thermal immersion results in a uniform distribution of plasmonic Au-NPs throughout the polymer matrix, preserving optical clarity and design fidelity. Structural, morphological, and spectroscopic analyses confirm the successful formation of plasmonic nanocomposites, exhibiting distinct localized surface plasmon resonance (LSPR) features in the 540–560 nm range. The plasmonic Fresnel lenses demonstrate tunable optical absorption, angle-dependent polarization sensitivity, and chromatic focusing behavior. Focal length measurements show minimal deviation from the designed geometry, while polarization studies reveal enhanced directionality and spectral modulation due to embedded nanoparticles. These findings highlight the synergy between additive manufacturing and in-situ nanomaterial synthesis, offering a promising route to multifunctional, nanostructured optical components for filtering, communication, sensing, and ophthalmic photonics applications.