Startup OPI Creates Ultra-Fast 3D Printing for Micro-Needle Patches

Microfabrication, a technique for creating micro-miniature 3D structures, holds great promise for many industries, including healthcare, biotechnology, electronics, and optics. Its economic and societal impact is limited by the fact that scalable production of complex microstructures is difficult, expensive, and often impossible using existing technologies.

Amsterdam-based startup Photosynthetic is breaking down barriers with an ultrafast 3D printer that can produce complex microscopic structures 1,000 times faster than existing technologies while maintaining extremely high precision. The company is initially focused on manufacturing Microneedle Array Patches (MAP), a painless alternative to hypodermic needles for delivering vaccines and drugs.

“Until now, there hasn’t been technology fast enough to produce high-quality microneedles, and there’s been no way to produce them with enough complexity and consistency to gain FDA approval,” said Dr. Magdalena Kurzyp, Chief Business Development Officer at Photosynthetic. “Our technology changes that, enabling the world to be vaccinated with self-administered patches and do so much more by harnessing the power of light to transform 3D printing.”

Pioneering next-generation advanced micromachining technology

Founded in 2020, Photosynthetic was originally conceived and patented in 2018 by CEO and founder Dr. Alexander Kostenko, then a postdoctoral researcher specializing in X-ray computed tomography (CT). He discovered that the computational algorithms used to reconstruct images in CT scans could be reversed to create physical 3D objects, leading to the development of Photosynthetics’ Volumetric Micro-Lithography (VML) technology.

Photosynthetic’s VML technology could be used in multiple markets to rapidly produce detailed and functional devices at lower cost. The company is initially focused on producing microneedles for vaccination, which are expected to be worth $3 billion to $10 billion by 2030.

“Microneedling enables consistent, room-based vaccination and self-administration, eliminating the need for a cold chain and professional administration,” Kurzyp said. “Our innovative needles with moving parts offer predictable dosing, providing a safer, more efficient alternative to traditional needles. They can be easily applied to the skin without fear of contamination.”

Photosynthetic plans to expand into microfabrication of micro-3D printed polymer chips for precision cancer diagnostics and personalized therapies, and is also investigating 3D printed, custom-designed tissue culture bioscaffolds that can be used to promote cell growth for non-animal drug testing. The company is also considering expanding into the micro-optics and photonics markets with 3D printed metalenses or diffractive optics.

The company turned to Rochester’s optics, photonics, and imaging (OPI) community to help build its business and expand into the U.S. market. Photosynthetic is one of 10 startups participating in Luminate NY, the world’s only accelerator program for startups developing OPI technologies.

“Luminate is giving us a head start by teaching us how to do business in the U.S., connecting us with qualified mentors and experts, and helping us establish our company here in Rochester,” Kurzyp said.

“Photosynthetic is working closely with OPI Companies in Rochester to develop and test their 3D printing technology in real-world applications,” said Dr. Sujatha Ramanujan, Managing Director of Luminate. “These important partnerships will help strengthen their product offerings and secure the resources and expertise they need to expand their business across the U.S. and globally—in healthcare and life sciences markets and beyond.”

Luminate is a program that helps startups working on OPI-enabled technologies improve their investment appeal and scale their businesses faster. Companies selected for the program receive an initial investment of $100,000 to participate in a six-month hybrid program, along with support to accelerate their path to commercialization. On September 26, at the 2024 Finals at The Theatre at Innovation Square, companies from Cohort 7 will compete for up to $2 million in follow-on investments. The program is funded by the Finger Lakes Forward Upstate Revitalization Initiative of Empire State Development. To learn more about the program and register to attend the 2024 Finals in person or via livestream, visit luminate.org.

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