Boston Micro Fabrication in Electronics Manufacturing: Precision in the Micrometer Range
The smaller the components, the greater the challenge for manufacturing technology. In electronics and connector technology, tolerances in the single-micrometer range are required. This is an area where traditional injection molding and machining processes reach their limits. This is precisely where Boston Micro Fabrication (BMF) comes in—a technology partner of AM Pioneers whose projection-based micro-stereolithography (PµSL) is now being used by leading electronics manufacturers.
What makes Boston Micro Fabrication unique?
BMF’s micro-3D printing systems, such as the microArch series, achieve resolutions of up to 2 micrometers, thereby enabling the additive manufacturing of components that were previously only feasible via micro-injection molding or precision machining. For companies looking to purchase a micro-3D printer, this is a crucial difference: the technology bridges the gap between a prototype and a production-ready component without requiring a new tool for every design change.
Case Study: Sonion NL and TE Connectivity Rely on Precise Microcomponents
Hearing aid manufacturer Sonion NL uses BMF’s PµSL technology (resolution up to 2 micrometers, tolerances of ±10 micrometers) to produce microcomponents that were previously manufacturable only via micro-injection molding. The key benefit: The time to the first test-ready component dropped from 1–2 months to 1–2 days, because the 4–6-week tooling process—including mold corrections—is completely eliminated. Sally van der Most, Development Support Services Manager at Sonion, describes the effect as follows:
“The quality and accuracy of BMF PµSL parts are truly unique; they closely mimic expensive micro-molded parts, and now we can have parts ready for testing within 1–2 days rather than 1–2 months.”
— Sally van der Most, Development Support Services Manager, Sonion NL
TE Connectivity, on the other hand, specifically uses the microArch S350—with an optical XY resolution of 25 micrometers, a positioning accuracy of ±1 micrometer, and six parallel projection zones for higher throughput—to manufacture high-resolution connectors for the aerospace, defense, and marine sectors. The Principal 3D Print Engineer in charge sums it up: The microArch S350 has become “a crucial tool,” precisely because of its combination of high part quality, production-ready throughput, and the ability to process a wide variety of materials.
Buying a Micro 3D Printer—What Matters
When selecting a micro printer technology for electronics manufacturing, three criteria should be prioritized: the resolution actually achievable in series production (not just on the datasheet), the availability of materials for high-temperature-resistant or biocompatible applications, and the ability to transition seamlessly from a single prototype to small-batch production. It is precisely in this consultation that the added value of an experienced technology partner lies.
AM Pioneers as a Partner for Micro 3D Printing
As a German partner of Boston Micro Fabrication, AM Pioneers helps companies in the electronics, medical technology, and precision manufacturing sectors find the right BMF system class for their specific application—from the 2-micrometer series for the highest precision requirements to the 25-micrometer class for larger components with shorter cycle times.
Would you like to determine whether micro-3D printing is suitable for your electronic components? Contact AM Pioneers for a no-obligation feasibility assessment using sample parts.
Erik Nitsche
Sales Engineer BMF
+49 162 764 2630
erik.nitsche@am-pioneers.com