Rapid prototyping of 3D microstructures: A simplified grayscale lithography encoding method using blender

The democratization of fabrication equipment has spurred recent interest in maskless grayscale lithography for both 2D and 3D microfabrication. However, the design of suitable template images remains a challenge. This work presents a simplified method for encoding 3D objects into grayscale image files optimized for grayscale lithography. Leveraging the widely used and open-source 3D modeling software Blender, we developed a robust approach to convert geometric heights into grayscale levels and generate image files through top-view rendering. Our method accurately reproduced the overall shape of simple structures like stairs and ramps compared to the original designs. We extended this approach to complex 3D sinusoidal surfaces, achieving similar results. Given the increasing accessibility and user-friendliness of digital rendering tools, this study offers a promising strategy for rapid prototyping of initial designs with minimal effort. • Creation of 2D grayscale digital masks from 3D models using free, open-source Blender software; • Incorporation of the calibration process in the design by appending color on the geometrical height; • Validated grayscale lithography method that reproduces in close comparison simple designs like stairs and ramps; • Demonstration by diverse microscopies that our method delivers complex shapes like sinusoidal surfaces and geometrical shapes.