NanoVoxel's efficiency with the micromanufacturing process unlocks new creative avenues for designers and engineers across diverse industries and changes the way in which to approach design and fabrication of intricate, customised, and functional micro-scale parts.

To answer this question NanoVoxel GmbH combines the best of both worlds, establishing the union of 2PP printing with micro-injection moulding its core business. By using 2PP 3D-printing to quickly produce a high-precision mould for the micro-injection, it replicates the precision and the resolution of 2PP in moulded micro-parts with highest efficiency. Picture 3 shows an example of a micro-gear moulded from one of these printed cavities.

About two decades ago, machine manufacturers, including WITTMANN BATTENFELD with its MicroPower 15 t, specialised injection moulding systems. These systems were tailored for precision micro-scale parts, offering industrial modularity and significant economic benefits. Despite this versatility and precision, the bottleneck in micro-part production persisted by their injection cavities, resulting in prolonged lead times of up to 20 weeks. Clients reluctantly accept larger tolerances (± 30 µm), but there's a growing need for shorter lead times, and smaller features, especially in prototype development. The time-consuming precision mould production lingers as the chief bottleneck.

High precision microparts are finding increasing relevance in different sectors including biomedical, consumer electronics, and many others. Most of the applications being developed require designs that require high precision, fast iterations, and challenge conventional design freedom.

To leverage the highest precision of the moulds, NanoVoxel uses the MicroPower 15 t (Picture 5) from WITTMANN BATTENFELD, a manufacturer of injection moulding machines and automation solutions. With a clamping force of 150 kN, the machines of the MicroPower series are designed for the economical production of exceedingly small and micro parts with maximum precision and repeat accuracy. A two-stage screw-piston injection unit with a shot volume of 1.2 to 6.0 cm3 injects a thermally homogeneous compound. This makes it possible to produce parts with outstanding precision, extremely stable production, and exceptionally short cycle times. The distinctive design of the machine allows the injection plunger to nearly reach the parting line of the mould. This reduces the mass cushion to a minimum. In addition, the standard version of the machine is already ideally suited for production under clean room conditions: it is designed with an enclosed housing cell. The housing cell offers enough space for the integration of equipment options like a rotary table, robot, material drier, and temperature control units. Robots and peripheral equipment from WITTMANN are specially adapted for this machine.

For example, current manufacturing methods such as CNC, EDM, mask-lithography, and SLA 3D printing struggle to quickly or precisely produce parts like micro-diffusors for acoustic applications featuring 70 µm 3D details (Picture 1); micro-lenses with a roughness below 10 nm; micro-needles with 5 µm tips; micro-nozzles with apertures under 20 µm; and micro-fluidic chips with specialised filters.

Through its commitment to advancing micromanufacturing technologies and re-imagining solutions, NanoVoxel welcomes unconventional part geometry and strives to provide a creative, efficient, and yet simple approach to manufacturing

All drive modules of the all-electric drive system, including all mechanical components, are encapsulated in easy-to-clean housings. The extremely well controlled injection of thermally homogeneous thermoplastics in exceptionally small quantities is necessary for successful injection moulding of precise and quality consistent mass production of micro-parts.

NanoVoxel, based in Austria, has innovated this approach that marks a significant advancement in the landscape of efficient and customised micromanufacturing.

However, this is made possible when two advanced technologies in micromanufacturing are combined: 2PP µ-3D printing and micro-injection moulding. This expertise is NanoVoxel's forte, a start-up founded in Vienna in 2022 to disrupt the industry standard of such micro-components.

Using 2PP printers, micro parts can be printed within hours from a 3D-CAD file with a precision that cannot be achieved by conventional toolmakers, even with the most advanced machinery. Tolerances below 1 µm, structures down to 200 nm, and surface finishes with an average surface roughness better than 10 nm can be produced quickly and economically with this advanced additive manufacturing. Geometries that cannot be produced through injection moulding, due to undercuts for example, can be produced quickly with 3D printing. Picture 2 shows an example of 2PP printed microneedle prototypes, emphasising sharp edges and micro-hollow structures.

High Density Polyethylene (HDPE) Market Analysis: Plant Capacity, Production, Process, Technology, Operating Efficiency, Demand & Supply, End-Use, Grade, Foreign Trade, Sales Channel, Regional Demand, Company Share, Manufacturing Process, 2015-2035

An example of NanoVoxel’s service is the development and manufacturing of an endoscope for the aiEndoscope company (Picture 4): the segments of the endoscope have been initially printed in different design variations at the prototyping stage for geometrical tests and optimisation. Upon design validation from the customer, the quickly moulded parts were produced and enabled functional and mechanical testing. All the manufacturing process and iterations on this project were completed within 5 weeks.

The limitations of both micro-moulding and micro 3D printing pose the question: What changes can expedite lead times, keep high precision, and still maintain high productivity?

The combination of 2PP printing and µ-injection moulding is not limited to only the high precision rapid tooling process. NanoVoxel GmbH brings a significant addition to the micromanufacturing industry with its capacity to 2PP print directly on parts of different materials manufactured with other processes. This print can be made onto many materials including glass, ceramics, carbon substrates, metals, and plastics. Moreover, the ability to combine varied materials for different functions offers customisability ideal for rapid prototyping, product development, and mass manufacturing. This enables customers to imprint detailed functional features directly onto bulky and larger parts obtained from more efficient processes. Initial applications have been successfully applied in the microfluidics world, where NanoVoxel printed unmouldable features into commercial chips, using their advanced printing process only where needed.

The capabilities of combining different processes including mastering, casting, and sintering, allow NanoVoxel to create moulds with the highest precision, not only from 3D printing materials but also with more robust materials like glass, ceramics, and metals.

During this week, the Asian HDPE market maintained stability with a slight price increase, particularly noticeable in imported PE film grades which experienced consecutive rises over two weeks. This was fueled by a shortage of Middle Eastern origins and escalating freight rates. Despite a cautious increase in demand and the film industry entering its off-season marked by restocking and terminal inquiries, order transactions remained subdued, exacerbated by weak downstream demand. Furthermore, the recent decrease in Crude oil prices has impacted production costs, partly due to the high-interest rate environment in the United States, which has suppressed demand, alongside bearish US inventory data and decreasing geopolitical risk premiums. These factors highlight the balance in the HDPE market, where supply constraints and fluctuating external factors shaped pricing dynamics amidst subdued demand.

The breakthrough in precision combined with economic efficiency has been achieved in recent years with the 2-photon printer of UpNano, a start-up also based in Vienna and a partner of NanoVoxel. This printer is based on the principle of non-linear absorption of photons, called two-photon polymerisation (2PP). A femtosecond laser emits a narrowly focused beam to excite a photosensitive resin. The scanner unit moves the laser beam via Galvano mirrors and lens systems to cure the resin. Like SLA/DLP 3D printing, when the light is absorbed, it triggers a chemical reaction in the resin, causing it to polymerise and solidify at the focal point of the laser beam. However, in a deviation from established 3D printing technologies, 2PP achieves full control of z-dimension polymerisation, so holes and cavities are precise and round. The 2PP printing process offers unparalleled precision and resolution to most other manufacturing techniques, enabling the creation of complex 3D micro-structures with sub-micron accuracy, even down to the nanometre range. This makes it ideal for applications requiring particularly intricate detail with high surface quality. A variety of photosensitive resins are available for 2PP printing, including photopolymers and hybrid materials. These materials can be tailored to specific applications and offer a wide range of mechanical, optical, and chemical properties.

Provisionally, the disadvantage of this technique is its capacity for high volume production, making it uneconomical for parts larger than a few mm.

Through the combination of the high precision 2PP µ-3D printing and the performance of the Micropower 15t micro injection moulding machine from WITTMANN BATTENFELD, NanoVoxel has successfully reduced the fabrication timeline of high precision micro-parts to two weeks.  Integration of these micro-manufacturing methods allows for swift prototyping and opens new possibilities in engineering and design across industries. With initial applications in biomedical and consumer electronics, the breakthrough includes the production of intricate microparts with unprecedented accuracy and design freedom.

The global High-density Polyethylene (HDPE) market experienced a variety of trends during the previous week. While HDPE prices in Europe and Asia surged due to increasing freight rates, prices in the US remained stable. These fluctuations were primarily driven by subdued demand and limited supplies worldwide. Further, production costs were influenced by fluctuations in feedstock Ethylene prices and a decrease in Crude oil prices. Moreover, disruptions in major supply routes caused by geopolitical tensions exacerbated market pressures. Consequently, Injection FD Hamburg (Germany) prices for European HDPE rose by 1%, Chinese HDPE Injection Molding EXW Jiangsu (China) prices saw a minor increase of 0.4%, and USA HDPE prices remained steady for the week ending on May 24, 2024. In Europe, the HDPE market experienced an upward trend driven by increasing freight rates, and low inventory levels in the regional market contributed to this rise. Further, higher costs of feedstock Ethylene supported the pricing of HDPE. However, demand from key sectors like construction, automotive, and packaging remained subdued in the domestic market. The surge in ocean freight demand from Asia, possibly signaling the start of a restocking cycle in Europe, along with North American importers accelerating their peak season demand due to concerns over labor issues or disruptions in the Red Sea later in the year, further strained the container market. This strain was worsened by the redirection of shipments from the Red Sea, leading to increased import costs of raw materials in Europe. Throughout this period, HDPE prices in the US remained stable, reflecting balanced supply and demand dynamics. Polyethylene trading significantly improved compared to the previous week, with prices for the most commonly traded grades remaining steady as business operations returned to normal. Despite rising freight rates from Asia to the Americas and shipping delays, export demand remained robust. However, international buyers continued to resist price increases, making incremental export sales challenging despite steady prices and limited prompt availability. Moreover, although feedstock Ethylene prices were increasing due to rising upstream Naphtha costs, HDPE prices remained unchanged. During this week, the Asian HDPE market maintained stability with a slight price increase, particularly noticeable in imported PE film grades which experienced consecutive rises over two weeks. This was fueled by a shortage of Middle Eastern origins and escalating freight rates. Despite a cautious increase in demand and the film industry entering its off-season marked by restocking and terminal inquiries, order transactions remained subdued, exacerbated by weak downstream demand. Furthermore, the recent decrease in Crude oil prices has impacted production costs, partly due to the high-interest rate environment in the United States, which has suppressed demand, alongside bearish US inventory data and decreasing geopolitical risk premiums. These factors highlight the balance in the HDPE market, where supply constraints and fluctuating external factors shaped pricing dynamics amidst subdued demand.

The global High-density Polyethylene (HDPE) market experienced a variety of trends during the previous week. While HDPE prices in Europe and Asia surged due to increasing freight rates, prices in the US remained stable. These fluctuations were primarily driven by subdued demand and limited supplies worldwide. Further, production costs were influenced by fluctuations in feedstock Ethylene prices and a decrease in Crude oil prices. Moreover, disruptions in major supply routes caused by geopolitical tensions exacerbated market pressures. Consequently, Injection FD Hamburg (Germany) prices for European HDPE rose by 1%, Chinese HDPE Injection Molding EXW Jiangsu (China) prices saw a minor increase of 0.4%, and USA HDPE prices remained steady for the week ending on May 24, 2024.

In Europe, the HDPE market experienced an upward trend driven by increasing freight rates, and low inventory levels in the regional market contributed to this rise. Further, higher costs of feedstock Ethylene supported the pricing of HDPE. However, demand from key sectors like construction, automotive, and packaging remained subdued in the domestic market. The surge in ocean freight demand from Asia, possibly signaling the start of a restocking cycle in Europe, along with North American importers accelerating their peak season demand due to concerns over labor issues or disruptions in the Red Sea later in the year, further strained the container market. This strain was worsened by the redirection of shipments from the Red Sea, leading to increased import costs of raw materials in Europe.

NanoVoxel aims to become a one-stop service platform offering flexible and multiple manufacturing solutions and strives to become one of the most innovative companies in the micro manufacturing world. NanoVoxel's multi-disciplinary team of experts combine these different technologies to offer prototypes through to high-volume production as a service provider. This remarkable accomplishment compresses the timeline for structure fabrication into an incredible two-week span.

Throughout this period, HDPE prices in the US remained stable, reflecting balanced supply and demand dynamics. Polyethylene trading significantly improved compared to the previous week, with prices for the most commonly traded grades remaining steady as business operations returned to normal. Despite rising freight rates from Asia to the Americas and shipping delays, export demand remained robust. However, international buyers continued to resist price increases, making incremental export sales challenging despite steady prices and limited prompt availability. Moreover, although feedstock Ethylene prices were increasing due to rising upstream Naphtha costs, HDPE prices remained unchanged.

NanoVoxel has since achieved a breakthrough in the moulding of micro-parts that was previously impossible to fulfil, enabling the moulding of small, detailed structures with high accuracy and repeatability within tolerances of a few microns. In addition, high-precision 2PP 3D-printing to create mould cavities enables larger parts with single-digit micron features, which would otherwise be time-consuming, expensive, or impossible to produce.