Precision micro printing vs. traditional micro production: accuracy, cost, time

Miniaturization of products brings new challenges in terms of accuracy, production times and costs. Traditional technologies such as micromachining, plastic injection moulding or micro lithography are running up against their limits when producing very small and complex parts - and this is where micro precision 3D printing comes in. This approach, based on Projection Micro Stereolithography (PµSL) technology developed by Boston Micro Fabrication (BMF), enables the production of parts with details that until recently were unattainable in industrial practice.

Precision in microns - where conventional tools end

Traditional microfabrication relies on mechanical processes that require extremely fine tools and a stable environment. Even under ideal conditions, accuracy typically reaches ±25-50 µm.
However, BMF microArch technology offers a resolution of up to 2 µm and dimensional accuracy of ±10 µm - up to five times higher accuracy than most micromachining methods.

Because the PµSL process is based on optical projection instead of mechanical contact, accuracy is not limited by tool wear or vibration. This eliminates scrap and geometric deformation of the material during machining. For the development of microfluidic chips, sensors, micro-optical parts or micro-mechanical assemblies, BMF technology is clearly a more accurate, faster and stable solution.

"Micrometer accuracy is no longer reserved for research labs or clean rooms. With BMF's PµSL technology, manufacturing companies can now achieve optical quality accuracy and surface finish that surpasses the limits of traditional microfabrication - without the cost, complexity and delays associated with moldmaking."

Robert Keogh, Sales Channel Lead EMEA, Boston Micro Fabrication

Cost: cheaper development and faster iterations

In conventional microfabrication, mould preparation, tooling and calibration form a significant part of the cost. Making a mould for a single prototype can take weeks and cost hundreds of thousands of crowns. In the case of 3D printing from BMF, no tooling preparation is required - data from the CAD model is simply transferred to the printing software and production can begin almost immediately.

This approach leads to a significantly shorter development cycle:

• Functional prototypes can be produced much more quickly than traditional manufacturing methods, where waiting for a mold can take several weeks.

• Design modifications or model iterations require no additional tooling costs or production delays.

• For small runs (tens to hundreds of units), micro 3D printing is often more cost-effective than conventional micro manufacturing.

This approach allows companies to quickly test multiple designs in sequence, reducing the risk of costly design errors and speeding new products to market.

Time: from weeks to hours

Conventional micromachining or injection moulding requires complicated tool preparation, calibration and debugging. Even a small design change can cause production delays of several days. In contrast, the BMF microArch S240 and S350 3D printers can produce a functional microcomponent a few millimeters in size in a matter of hours to a day.

For example, a microfluidic chip with channels 200 µm in diameter can be printed in about 2.5 hours, while it can take 3-5 days to produce by milling or etching. This time saving, combined with high repeatability, enables efficient small batch production without the need for costly preparation or tooling.

Conclusion

BMF microArch technology is changing the established paradigm of microfabrication. Where previously moulds, etching and micromachining dominated, micro 3D printing with optical precision is now emerging. It brings not only greater flexibility but also cost-effectiveness in developing products with millimeter dimensions and micron details.

For companies that want to speed up development while improving the quality of their micro components, BMF technology is the path to faster, cheaper and more accurate production - without compromise.

For more information, click here BMF 3D Printer or visit www.bmf3d.com.