Laser-Based Microscale 3D Printing Advances Space and Defence Manufacturing

Australian researchers have demonstrated a laser-based manufacturing process that enables true three-dimensional fabrication at the microscale, addressing a longstanding challenge in space and defence engineering. Developed through a SmartSat-supported PhD project at La Trobe University, the technique allows complex, multi-material structures to be grown directly from gas. The approach supports emerging satellite and defence systems operating at millimetre-wave and terahertz frequencies, where precision, compactness and material performance are critical. Details of the research were published by SmartSat CRC.

Addressing manufacturing limits at terahertz scales

Modern satellite, defence and high-altitude communication platforms are increasingly moving toward millimetre-wave and terahertz (THz) frequencies to support faster and more secure data transmission. Components operating in this spectrum typically range from 10 micrometres to 1 millimetre in size, pushing the limits of conventional manufacturing methods.

Existing fabrication techniques often struggle to produce the complex three-dimensional geometries required at these scales, particularly when advanced materials such as ceramics, carbon and metals must be combined. These constraints have slowed progress across Australia’s space, defence and advanced materials sectors, where smaller, lighter and higher-performing components are increasingly important.

Growing 3D structures directly from gas

The new process, developed by Dr Vibhor Thapliyal during his PhD in Advanced Manufacturing at La Trobe University, uses focused laser energy to grow solid materials directly from gas-phase precursors. This enables structures to be fabricated vertically and laterally in three dimensions without the need for moulds, supports or post-processing assembly.

“This research pushes the boundaries of advanced manufacturing in Australia. It shows how we can build complex 3D structures at the microscale to control signals in ways that were not previously possible, unlocking new opportunities for space and defence technologies.” — Vibhor Thapliyal, Researcher, La Trobe University

Over the course of the research, more than 600 individual fibres were successfully grown using carbon- and titanium-based precursors. These fibres were stacked in a precise grid to form a three-dimensional lattice, demonstrating a high degree of control, repeatability and material integration.

Demonstrating photonic crystals for THz applications

The assembled lattice was used to create a three-dimensional photonic crystal designed to control and filter electromagnetic signals. Simulations confirmed that the structure operates within the 0.12–0.14 THz range, demonstrating the feasibility of the laser-based process for real-world photonic and metamaterial devices.

Unlike traditional fabrication approaches, the technique enables multiple materials to be integrated within a single microscale structure. This capability is particularly relevant for frequency-selective filters and signal control components required in secure communications and sensing systems.

Implications for Australia’s space and defence priorities

The research establishes a new advanced manufacturing capability in Australia, aligned with national space and defence priorities. By enabling smaller and lighter components with high performance at terahertz frequencies, the process supports the development of next-generation satellite hardware, sensing technologies and secure communication systems.

The work also complements broader efforts to strengthen Australia’s innovation pipeline in advanced manufacturing and materials science, including university–industry initiatives such as industry-ready research programs and targeted funding for advanced materials and space-related research.

Pathway to deployment and future research

Beyond laboratory demonstrations, the manufacturing process is designed to be scalable and adaptable, supporting future industrial deployment. For defence manufacturing, this opens pathways for compact sensing and surveillance devices, advanced frequency-selective filters and new classes of metamaterials.

The next phase of the project will focus on experimental validation of terahertz performance in operational systems. Future research will also explore actively tunable photonic devices, integration with micro-electromechanical systems (MEMS), expansion to new material systems and additional defence applications. These developments sit alongside wider national priorities in emerging technologies, including those highlighted in discussions on how AI, quantum and robotics are shaping future growth.

Dr Thapliyal has recently completed his PhD and is seeking roles in research and development or postdoctoral research, with expertise spanning laser-based processing, additive manufacturing and experimental R&D for space and defence applications.