How DNA 3D Printers May Transform Microchip Design

A team of scientists from multiple prestigious learning institutions just unlocked the key to nano-scale fabrication. Their novel approach utilizes a specially built DNA 3D printer. This completely new approach to fabricating targeted 3D nanoscale structures relies on the predictability and self-assembly characteristics that DNA possesses. Interestingly, the technology utilizes modular DNA structures that can link together to form larger architectures. These structures can help to drive advanced technologies such as neuromorphic computing, thermal decoupling, and future microchip design. Here’s what you need to know.

Why Nano-Scale Fabrication Matters

The age of small-scale fabrication has led to major technological breakthroughs. Miniaturization of core computational components has allowed engineers to create microelectronics that would seem like sci-fi only 5 years prior.  However, even advanced chips that rely on photolithography to laser etch stencils are limited in their ability to be miniaturized.

Technologies such as additive manufacturing have helped to push small-scale fabrication methods further, but they have been bottlenecked recently. As nano-fabrication becomes the next stage in miniaturization, these technologies have fallen short due to the unique requirements needed to create nano-sized structures. Notably, nanostructures are ideal for high-tech science applications as they provide superior bond strength, structural support, and can assist in the transport of heat or electricity if needed.

The Challenges of Printing Microelectronics

The problem with using 3D printers to create nanoscale projects is that their sheer size makes it impossible to ensure that they will retain their structure. This problem becomes even more relevant when dealing with complex three-dimensional structures.

How the DNA 3D Printer Works

Recognizing these limitations and the need to explore the nano-fabrication process further, a team of engineers from Columbia and Brookhaven National Laboratories released the “Encoding hierarchical 3D architecture through the inverse design of programmable bonds” study¹.

This paper explores the potential of utilizing DNA as a 3D printing material. DNA has some unique qualities that make it ideally suited for this task. For one, it self-assembles due to natural reactions. This bio-organization means that these structures will form once printed without additional steps.

Source – Natural Materials

Why DNA is Ideal for Nano-Printing

The engineers predicted that DNA would be the perfect solution to nano-fabrication for several reasons. For one, it can only fold in certain ways based on the four nucleic acids. This predictability makes it easier to create sturdy structures that don’t require extra steps to assemble. Additionally, they make the structure mechanically robust and durable.

Voxels: The DNA Building Blocks

The scientist decided that an eight-sided octahedral shape called a voxel would be the best approach. Voxels form strong bonds at exact locations at the corners of each unit. Additionally, they can be grouped predictably to create a larger structure.

According to researchers, one of the most complicated steps of the entire experiment was determining how to set up the starting sequence for the voxels to create the intended structures. DNA structure can include billions of points. Thankfully, the voxel’s unique characteristics ensured that an inverse structural design was possible.

MOSES: The DNA Origami Design Tool

The engineers called their approach to nano-fabrication a bit like “DNA origami.” This name refers to how the DNA is set up to fold in certain ways based on the coding directions provided by the engineers. To accomplish this task, the team needed to create a computational model.

They developed the system called Mapping Of Structurally Encoded Assembly (MOSES) to act as a design studio for their creations. The software allows scientists to arbitrarily define a 3D hierarchically ordered lattice and verify its capabilities before printing.

Engineers can even develop nano designs that have cargo within them. This cargo can be used to ensure that the targeted hierarchically organized structure remains durable. Also, the computer model was crucial in helping engineers fine-tune their DNA structural design, allowing engineers to test different DNA structures and materials.

How DNA Self-Assembly Works

The DNA naturally binds at its connector points, eliminating the need for any additional production. This process occurs in special water wells and doesn’t create any harmful waste chemicals. Reducing the time and effort it takes to create crucial nano structures, like catalytic materials and biomolecular scaffolds.

Designing for Maximum Efficiency

The computational model helped to ensure that the engineers only used the minimal amount of DNA to create a structure. This strategy ensures that the structure is its most efficient version, helping to increase the productivity of the process.

Turning DNA Prints into Durable Structures

When the nanoscale prints were completed, they were coated with silica. The next step was to heat them. Once at a desired temperature, the DNA used to print the structure decomposes into an inorganic form. This strategy increases the durability and lifespan of the prints.

Testing the DNA 3D Printer

The engineers tested their work at the Columbia and Brookhaven National Laboratories. Specifically, the team utilized synchrotron-based X-rays and electron microscopes to examine the DNA structures and stress test their capabilities.

As part of the testing phase, the team printed multiple items. The first prints included low-dimensional elements. The next designs included helical motifs, a face-centred perovskite crystal shape, and a distributed Bragg reflector. Notably, these shapes provided unique characteristics built into their design.

What the DNA 3D Printer Tests Showed

The results showed that the nanostructures matched the computer model predictions exactly. They self-assembled as predicted and demonstrated the added resilience compared to previous methods of small-scale fabrications. Additionally, the engineers noted that using different materials provided different characteristics to the structure.

For example, the introduction of gold nanoparticles provided some of the tested structures with desirable optical properties for laser computing and more. The same concept could be used to create materials that are super heat-resistant or can transfer electrical pulses seamlessly.

Key Benefits of DNA 3D Printing

There are several benefits to the DNA 3D printer study that will improve technologies. For one, nanofabrication is the evolution of today’s most advanced small-scale fabrication methods. As such, Nano printing will open the door to smaller and more powerful microelectronics, computers, and healthcare devices.

Automatic Self-Assembly

The use of voxels provides the 3D printed designs with a strong support structure that can be set up to self-assemble into any desired shape. This approach offers structural fidelity and eliminates the need to conduct post-print steps, reducing errors and improving efficiency.

Lower Costs & Efficiency

Additive manufacturing has helped to reduce the fabrication costs of unique products. This strategy will enable engineers and scientists to take cost reductions a step further by eliminating any need for assembly. Keenly, these prints follow the DNA’s natural course, providing significant savings compared to other options.

Eco-Friendly Manufacturing

The nanostructured form in water directly, meaning that there is no need to utilize harmful chemicals. As such, there are very few pollutants. Additionally, the computer model automatically utilized the least amount of DNA possible, further reducing any chance of wasted materials wherever possible.

Versatile Materials & Uses

Interestingly, this approach is not regulated to bio-derived components. The engineers stated that their approach can utilize both inorganic and bio-derived nanocomponents to make durable scaffolds. This flexibility enables engineers to create unique and more functional prints designed for specific tasks.

Real-World Applications & Timeline

There are several applications for the science explained in the DNA 3D printing study. For one, it will help to drive innovation and miniaturization across industries. High-tech devices built from nanoscopic building blocks could conduct a broad range of applications, like monitoring your health internally or keeping spacecraft engine temperatures in check.

Next-Gen Optical Chips & Neuromorphic Computing

One of the primary uses for 3D DNA printing is to build more advanced computers. Many believe that optical computers are the future. The team hopes their work will help to further the creation of nano 3D light sensors, which can be easily integrated onto microchips. According to their study, light-sensitive material can be applied to the nano scaffolds to accomplish this task.

When Could DNA 3D Printers Become Reality?

It could be +10 years before this technology makes its way to the public. There are a lot of different directions this technology will go, including liquid robotics automation and even creating artificial brains. Each of these examples will take nearly a decade to fully investigate and deploy.

Who’s Behind the Research?

The DNA 3D printing study was led by researchers from multiple prestigious universities, including Columbia University and Brookhaven National Laboratory’s Center for Functional Nanomaterials. The paper lists Brian Minevich, Sanat K. Kumar, and Aaron Michelson as contributors to the project. They worked with a team of scientists from numerous universities to bring the project to life.

What’s Next for DNA 3D Printing?

The future of DNA 3D Printers will include a variety of industrial and medical uses. These devices will be used to create high-tech devices and improve the characteristics of crucial components, including thermal management. The team noted that it will continue to expand on its research, including delving into other materials and uncovering new design principles to streamline the assembly of complex structures.

Investing in the Future of Microchips

There are several companies involved in creating microcomputer chips. Demand for these tiny devices has seen considerable growth as the use of high-tech devices has become the norm globally. The introduction of nanochips will further the miniaturization of electronics and open the door for more complex and effective devices. Here’s one company that remains a leader in microchip fabrication.

Applied Materials 

Applied Materials (AMAT -1.29%) was founded in 1967 by Michael A. McNeill to service the semiconductor wafer industry. The company launched in Silicon Valley and has grown to become a global leader in microchip wafer production.

Notably, Applied Materials remains a popular stock for investors seeking exposure to the chip sector. The company went public back in 1972 and has since remained a top performer on the NASDAQ. In the early 80s, the company began servicing Asia with the launch of a new plant in Japan. This move opened the door for international clientele.

Today, Applied Materials is one of the best-known names in wafer production. The company has invested millions into improving microchips and owns some of the most diverse semiconductor chip production machines in the world. Those seeking a global leader in chip manufacturing should do more research into AMAT.

Latest Applied Materials (AMAT) Stock News and Developments

Final Thoughts

When you hear about DNA printers, you may envision some device creating a living creature. However, these engineers have shown that DNA could create the perfect scaffolding for other unique materials on a nanoscale. Consequently, their work will help to advance microelectronics and hopefully inspire further discoveries in the sector.

Learn about other cool additive manufacturing breakthroughs now.

References:

^{1. Kahn, J.S., Minevich, B., Michelson, A. et al. Encoding hierarchical 3D architecture through inverse design of programmable bonds. Nat. Mater. (2025). https://doi.org/10.1038/s41563-025-02263-1}