What is micro 3D printing and when do you need it

In an era of miniaturization and increasing demand for high-precision components, micro-precision 3D printing technology is coming to the fore. This method, also known as micro-scale additive manufacturing, enables the production of components with a resolution of up to 2 µm and dimensional accuracy of ±10-25 µm. Compared to established additive manufacturing and prototyping technologies such as MJF, SLA or FDM, micro 3D printing pushes the boundaries of detail, surface quality and functionality.

How micro precision 3D printing works

At the heart of the technology is the Projection Micro Stereolithography (PµSL) process, which uses the projection of UV light through a digital micromirror array (DMD) to precisely cure a photopolymer resin. Each layer is only 2 to 40 micrometers thick, allowing the printing of miniature structures with fine channels, thin-walled geometries or complex internal cavities. This makes micro-precision printing an ideal tool for manufacturing microfluidic chips, connectors, sensors or biomedical implants.

BMF microArch technology

Boston Micro Fabrication (BMF) is a global leader in micro 3D printing, offering a range of microArch systems designed to cover a wide range of application and resolution requirements. Each 3D printer in this line utilizes patented Projection Micro Stereolithography (PµSL) technology to deliver exceptional accuracy, repeatability and productivity - enabling engineers to produce parts that were previously too small or too complex for any traditional manufacturing method.

microArch S230

The microArch S230 is the highest precision system in the BMF portfolio. It offers 2 micrometer optical resolution and ±10 µm dimensional accuracy , making it the ideal choice for research facilities and applications requiring extreme precision and detail.

microArch S240

The microArch S240 3D printer strikes a balance between precision and productivity - with a resolution of 10 µm and a tolerance of ±25 µ m, it is designed for both prototyping and small batch production of functional components.

microArch S350

The microArch S350 offers 25 µm resolution and ±50 µm accuracy , making it suitable for larger or more complex parts that still require micro-level accuracy.

microArch D1025

Completing the lineup is the microArch D1025 system, which brings innovative dual resolution - combining 10µm and 25µm optics within a single device. This unique approach allows users to print different parts of the same model at different resolutions, optimizing both fine detail and build speed within a single print job.

Across the microArch series, users can benefit from layer thicknesses from 5 to 50 µm and a wide compatibility of materials including photopolymers, ceramic and biocompatible resins.
Together, these systems provide designers and manufacturers with the tools to push the boundaries of miniaturization and redefine the possibilities of micro 3D printing.

These parameters make it possible to produce parts that cannot be achieved with conventional 3D printing methods or precision machining. PµSL technology also has the advantage of a high accuracy to time efficiency ratio - printing a miniature sensor or micro-mechanical part takes on the order of minutes to units of hours, not days.

"Micro 3D printing represents a major breakthrough in how we design and manufacture miniature devices. For the first time, engineers can now achieve micrometer accuracy and surface quality comparable to injection molding - without the limitations of traditional tooling."

Rob Keogh, Sales Channel Lead EMEA, Boston MIcro Fabrication

When do you need micro 3D printing

BMF's micro precision printing is primarily used where millimeters and micron tolerances are critical:

• Healthcare and biomedical sector: microimplants, lab chips, microfluidic systems.
• Electronics and sensors: mini connectors, chip carriers, parts for optical sensors.
• Micromechanics and research: components for clocks, robotic systems, educational applications.

Compared to conventional technologies, which achieve 50-100 µm layers, BMF's 3D printing offers more than 20x higher precision as well as better material isotropy. This makes it possible to print functional micro parts that are not only accurate but also mechanically stable.

Conclusion

Micro-precision 3D printing brings to the industry what seemed like science fiction a few years ago - the ability to produce functional components the size of a grain of rice with a precision that only micro lithography could previously manage.
Thanks to BMF microArch 3D printers, such precision may be available to developers, labs and manufacturing companies looking to innovate at the micro scale.