Integrated 3D-printed Raman spectrometers: rapid manufacturing and structural insights via CT-based analysis

Purpose Compact optical systems often face long fabrication and verification cycles that slow early-stage development. This study aims to shorten the development cycle of compact optical systems through rapid manufacturing and integrated validation. Design/methodology/approach An integrated design methodology combining optical simulation, additive manufacturing and nondestructive inspection is proposed. Mechanical structures for compact optical assemblies are fabricated using 3D printing. X-ray computed tomography (CT) is used to evaluate printing and assembly accuracy without disassembly. A Raman spectrometer is used as a demonstrator, in which both Czerny–Turner (C-T) and crossed C-T configurations are designed, printed, assembled and experimentally tested. Findings The experimental results show that clear Raman signals can be detected within an integration time of 0.5 s, demonstrating that the 3D-printed mechanical structures provide sufficient stability and alignment accuracy for functional optical performance. CT inspection successfully reveals manufacturing and assembly deviations, enabling rapid assessment and iteration of the system design. Originality/value This work presents a novel workflow that integrates simulation-driven design, rapid additive manufacturing and CT-based nondestructive inspection for compact optical systems. The proposed approach significantly shortens the development cycle and provides an efficient pathway for rapid iteration and early validation of functional optical instruments.