[Breaking Taps] has done some lithography experiments in the past, including some test patterns and a rudimentary camera sensor. But now, it’s time to turn it up a notch with 1µm garage semiconductor ambitions.

The e-beam lithography he’s done in the past can achieve some impressive resolutions, but they aren’t very fast; a single beam of electrons needs to scan over the entire exposure area, somewhat like a tiny crayon. That’s not very scalable; he needed a better solution to make 1µm semiconductors.

In his quest, he starts by trying to do maskless photolithography, using a literal projector to shine light on the target area all at once. After hacking a projector devkit apart, replacing blue with ultraviolet and adding custom optics, it’s time for a test. The process works for the most part but can’t produce fine details the way [Breaking Taps] needs. Unfortunately, fixing that would mean tearing the whole set-up apart for the umpteenth time.

In either a genius move, or the typical hacker tangent energy, he decides not to completely re-build the maskless lithography machine, but instead uses it to create masks for use in a 10:1 reduction machine, also known as the more traditional mask photolithography. In the end, this works out well for him, reaching just about 2 µm effective minimum feature size in this two-step process.

We haven’t even remotely covered everything and there are, of course, always things to improve. And who knows? Maybe we’ll see 1µm semiconductors from [Breaking Taps] in the future.

Here on Earth, being able to 3D print replacement parts is handy, but rarely necessary. If you’ve got a broken o-ring, printing one out is just saving you a trip to the hardware store. But on the Moon, Mars, or in deep space, that broken component could be the difference between life and death. In such an environment, the ability to print replacement parts on demand promises to be a game changer.

Which is why the recent successful test of a next-generation 3D printer developed by a group of Berkeley researchers is so exciting. During a sub-orbital flight aboard Virgin Galactic’s Unity spaceplane, the SpaceCAL printer was able to rapidly produce four test prints using a unique printing technology known as computed axial lithography (CAL).

NASA already demonstrated that 3D printing in space was possible aboard the International Space Station in a series of tests in 2014. But the printer used for those tests wasn’t far removed technologically from commercial desktop models, in that the objects it produced were built layer-by-layer out of molten plastic.

In comparison, CAL produces a solid object by polymerizing a highly viscous resin within a rotating cylinder. The trick is to virtually rotate the 3D model at the same speed as the cylinder, and to project a 2D representation of it from a fixed view point into the resin. The process is not only faster than traditional 3D printers, but involves fewer moving parts.

Lead researcher [Taylor Waddell] says that SpaceCAL had already performed well on parabolic flights, which provide a reduced-gravity environment for short periods of time, but the longer duration of this flight allowed them to push the machine farther and collect more data.

It’s also an excellent reminder that, while often dismissed as the playthings of the wealthy, sub-orbital spacecraft like those being developed by Virgin Galactic and Blue Origin are capable of hosting real scientific research. As long as your experiment doesn’t need to be in space for more than a few minutes to accomplish its goals, they can offer a ticket to space that’s not only cheaper than a traditional orbital launch, but comes with less red tape attached.