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3D Printed Chip Packages Could Supercharge Semiconductor Manufacturing

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3D Printed Chip Packages Could Supercharge Semiconductor Manufacturing


AUSTIN, Texas — Engineers at The University of Texas at Austin are leading an academic and industry all-star team that aims to revolutionize the production of semiconductor chips with a new 3D printing method. The new approach, which the researchers are calling Holographic Metasurface Nano-Lithography (HMNL), aims for faster, more efficient and environmentally friendly production of advanced electronics.

HMNL has applications ranging from smartphones to robotics to aerospace. It can create designs that were previously impossible, such as 3D printed capacitors, which store energy in electronic devices, or electronic packages that fit into unconventional spaces. For example, it would make it possible to embed artificial intelligence in customized configurations to fit the specifications of robots or rockets.

“Our goal is to fundamentally change how electronics are packaged and manufactured,” said Michael Cullinan, an associate professor in the Cockrell School of Engineering’s Walker Department of Mechanical Engineering, who is leading the team. “With HMNL, we can create complex, multimaterial structures in a single step, reducing production time from months to days.”

The team, comprising researchers at the University of Utah, Applied Materials, Bright Silicon Technologies, Electroninks, Northrop Grumman, NXP Semiconductors and Texas Microsintering, has received a $14.5 million grant from the Defense Advanced Research Projects Agency (DARPA) to pursue this work.

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Electronics manufacturing today is a complex, time-consuming process that involves layering materials one step at a time. This approach not only limits design flexibility but also generates significant material waste. HMNL offers a faster, more sustainable alternative.

The key to this technical leap lies in metasurfaces, which are ultra-thin optical masks capable of encoding high-density information. When exposed to light, these metasurfaces create holograms that enable the simultaneous patterning of a hybrid resin made of metal and polymer into intricate 3D structures. The process is so precise that it can achieve resolutions smaller than the width of a human hair.

Additionally, by eliminating multiple production steps and reducing material waste, the process minimizes the environmental footprint of industrial activities. The increased speed will make it easier to develop unique prototypes.

The researchers created four prototypes as part of this project for a variety of applications:

  • Commercial electronics: A fan-out module for consumer devices, showcasing faster production and improved design flexibility.
  • Defense systems: Advanced prototypes for high-frequency communication and reconfigurable electronics.
  • Nonplanar designs: Electronics packages that fit into challenging spaces.
  • Active packages: Structures that serve mechanical and electrical functions, such as precise beam-pointing systems for optical applications.

“This isn’t just about making electronics faster or cheaper; it’s about unlocking new possibilities,” said Cullinan.

The researchers plan to commercialize the technology through Texas Microsintering Inc., a startup founded by Cullinan.

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Austin, TX

Joint Venture Acquires 243-Bed Student Housing Community Near University of Texas at Austin

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Joint Venture Acquires 243-Bed Student Housing Community Near University of Texas at Austin


AUSTIN, TEXAS — A joint venture between Ascentris and Student Quarters has acquired Noble 2500, a 243-bed student housing community serving students at the University of Texas at Austin. Built in 2023, the property is located in Austin’s West Campus neighborhood and offers 118 fully furnished units in studio, one-, two-, three- and four-bedroom configurations with bed-to-bath parity. Shared amenities include study lounges, a courtyard pool, fitness center, yoga studio and a rooftop sky lounge. The new ownership plans to enhance the property’s common areas and implement operational improvements to boost leasing performance. The seller and sales price were not disclosed.



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Austin, TX

Long TSA lines return at Austin airport as shutdown drags on, pay order offers hope

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Long TSA lines return at Austin airport as shutdown drags on, pay order offers hope


Long security lines returned to Austin-Bergstrom International Airport on Sunday as the partial government shutdown continued, prompting some travelers to arrive hours early and still worry they might miss their flights.

Some travelers said they showed up four hours ahead of departure to try to avoid problems at the checkpoint. Inside the terminal, security lines stretched across the building, testing patience as passengers waited to be screened.

“This has been insane. Hopefully they get it figured out,” traveler John Wittle said. Another traveler, Juliana Sombrano, said, “We arrived four hours earlier today because they said the lines were going to be really long today.”

Airport officials said they were expecting about 32,000 travelers Sunday. The airport typically considers anything over 30,000 to be a busy travel day.

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The congestion contributed to travel disruptions for some passengers. “American cancelled our flight. Didn’t tell us anything about what to do. Our bags are in a completely different city right now,” traveler Michael Vosicky said.

The extended TSA lines have also affected other Texas airports, including Bush Intercontinental Airport in Houston. TSA agents have not been paid in more than 40 days as the partial shutdown has continued, leaving some travelers sympathetic to workers.

“Obviously feel sorry for the staff who are going through everything,” traveler Michael Radomir said.

ALSO: One person critically injured after vehicle collides with motorcycle in NW Austin

On Friday, President Donald Trump signed an executive order authorizing TSA agents to be paid with Department of Homeland Security funds, while blaming Democrats for the airport controversy. “Some of them are needing money because the Democrats cut off their money. I blame the Democrats more than anything else,” Trump said.

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The order came as House Republicans rejected a bipartisan Senate bill that would have fully funded the TSA and several other agencies.

At Austin-Bergstrom, travelers said they hope paying TSA workers will help speed up screening lines. “Hopefully it does nothing but continue to improve everything, everything that we’re seeing here,” traveler Mark Lupkey said.

TSA said agents could begin getting paid as early as Monday. The agency did not confirm how many agents have not been working in Austin since the partial shutdown began.



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Austin church to use 3D printing for new campus

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Austin church to use 3D printing for new campus


AUSTIN, Texas — The housing market has cooled, with J.P. Morgan predicting house prices in the U.S. will stall. Despite the stagnate home price analysis, one Texas-based tech company is developing an unconventional way to build. An Austin church is tapping into ICON’s 3D printing technology to rebuild its church campus.

St. Mark’s Episcopal Church has been on its 8-acre property since the late 1950s.

“We’ve long been in this kind of predicament here as a congregation that we have these really deep-level structural problems with our buildings, and we’ve really never been able to imagine being able to pay for it,” said Father Zac Koons, the leader of the church.

He said costly quotas to repair aging infrastructure is one big reason they partnered with ICON to develop a whole new church campus.

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“It’s not only a less expensive or a more affordable way to build, it’s also a more environmentally friendly way to build,” Koons said.

ICON’s “Titan” construction system will be used for this project, bringing the world’s first 3D-printed church to Austin.

“I think this will be a famous building,” said Jason Ballard, the CEO and co-founder of ICON. “I think it will stand for hundreds of years, and I think they’re just so pleased with what they’re able to get on their budget out of this building.”

The company says its concrete mixture can save future homeowners and businesses roughly 40% compared to conventional wood and metal frameworks. 

“For the past two years, we have been working on a second generation of printer technology that is multi-story, easier to set up, easier to operate, even lower cost, even faster,” Ballard said.

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Had it not been for the partnership with ICON, Koons said his church would not have been able to afford such a large-scale project. 

“We wouldn’t have been able to do something as ambitious as we’re talking about doing without ICON, for sure,” Koons said.

He said they’ll break ground in about a year, with hopes to finish the first building by the summer of 2028.



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