Innovative test specialist manufactures connectors in small batches
Technical progress requires courage – BRIGHT proved this in a challenging project for a leading car manufacturer. The company realized the innovative solution with precision micro stereolithography from Boston Micro Fabrication (BMF): its partner AM Pioneers prints high-precision connector plates for plug connectors in stable synthetic resin on a microArch S240 3D printer with 10 µm resolution in Esslingen.
As a development partner for the mobility sector, BRIGHT, with locations in Böblingen and Munich (Germany) among others, offers a wide range of products and services to support the usual test processes in this sector. The innovative team of more than 100 people is a development partner to the mobility sector – from the automotive industry, aerospace and rail technology to agricultural and construction machinery. Peter Hautke, General Manager Sales and Operations E/E, received an inquiry in 2024 regarding test equipment for the control units of a new generation of vehicles.
Testing the electronic nervous system
Control units form the intelligent nervous system of modern automobiles. They control ignition and fuel injection as well as automatic air conditioning, safety and driver assistance systems. The networked devices receive signals from sensors and set actuators in motion – the slightest malfunction can trigger disasters. “Before new vehicle models go into series production, developers and quality engineers want to know very precisely how the various control units actually work with the series wiring harness,” reports Peter Hautke. In order to connect the measurement technology behind the control units, a y-shaped adapter cable is connected in between. BRIGHT was asked to develop and supply this. “We can buy the plug and socket between the control unit and the series cable,” says Hautke, “the difficulty lies in the connectors at the junction for the measurement technology.”
The solution was to scan the conventional socket, redesign the 3D model and then 3D print it. However, the connector plate inside has to accommodate around 100 gold-plated pins with very tight shape and position tolerances – otherwise individual pins would break off. “Reliable 3D printing of the required 18 variants in series of 150 pieces with the required tolerances was previously not possible,” says Peter Hautke. “But we were sure that our partner AM Pioneers could solve the problem with a new 3D printing process.”
Precision micro stereolithography from BMF
AM Pioneers GmbH in Esslingen has been supporting manufacturing companies in the implementation of various 3D printing technologies since 2021 – with 3D scans, as a service provider for engineering and manufacturing and as a reseller of printing systems. The company focuses on leading manufacturers such as Desktop Metal, 3DCeram and Boston Micro Fabrication (BMF) for microfabrication. Projection Micro Stereolithography (PμSL) from Boston Micro Fabrication (BMF) improves digital light processing for micro applications. The printing systems contain high-precision optics to focus the pixel size in the projector to 25μm, 10μm or 2μm, depending on the printer series. The linear technology of the 3D printers was also designed for the lowest tolerances.
AM Pioneers has owned a microArch S240 from BMF since 2023. With a resolution of 10µm and a build volume of 100 x 100 x 75 millimetres, it is suitable for prototypes and series of micro components in final quality. “The S240 combines high accuracy and precision with the reproducibility that is crucial for our projects,” explains Frederik Nussbaumer, Head of Sales at AM Pioneers. “We were sure that we would be able to print the connector plates within the specified tolerances of 20 µm.”
Proof of concept
Now all BRIGHT had to do was convince the skeptical customer. Together with AM Pioneers, they took a risk and supplied free sample parts that met all the requirements. With the presentation of the underlying technology and other reference parts, they were able to convince the car manufacturer – who can look forward to considerable advantages over conventional production methods. “The complete elimination of tool costs for the injection molding process, the time saved and the significantly greater flexibility for late changes and improvements weigh heavily,” explains Peter Hautke. “Even more important, however, is the increase in safety during the extensive testing of the critical control technology.”
Problem-free small series and variant production
By the middle of next year, the partners will now be able to produce 18 variants of the connector in small batches of 150 units, i.e. a total of 2,700 components, on the 3D printer and deliver them with the cable sets. “We can produce 20 parts in one setup,” reports Frederik Nußbaumer. “We benefit from the high process stability of the machine, which we can run overnight without any problems.” HTL, a high-performance polymer from BMF that is available in various colors and also transparent, is used for this purpose. In this case, the most stable material was chosen in black. “The wide range of available materials, transparent, biocompatible and particularly durable resins are an important selling point for us,” says Frederik Nußbaumer. The installation, instruction and user training were completed by BMF in four days. Since then, AM Pioneers has only occasionally needed support from the manufacturer: “We find it very impressive how quickly BMF responds to technical questions,” says Frederik Nussbaumer, praising the partnership-based cooperation with BMF.
Conclusion
AM Pioneers uses the machines for series production, contract manufacturing of prototypes and as demonstration units, as in this project. “The microArch S240 has proven itself as a real production tool thanks to its repeat accuracy and process stability,” says Frederik Nussbaumer. “With the right engineering and additive manufacturing expertise, it can give you a real competitive edge.” The first order from the car manufacturer will not be the last: Various vehicle variants are still in development and are also being tested. “In a price-sensitive environment, we work with our developers and partners every day to find the best solutions for our customers through expertise, innovative ideas and courage,” concludes Peter Hautke. “This approach has proven its worth in our collaboration with AM Pioneers and BMF.”
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About BRIGHT
The BRIGHT Group is a merger of various technology companies and today combines the key competencies for research and development departments in the mobility sector. With over 100 employees and more than 1,000 successfully implemented projects, BRIGHT supports companies in the automotive, aerospace, rail technology, agricultural and construction machinery sectors. As a development partner at the Böblingen, Esslingen and Munich locations, we think in terms of technology, interdisciplinarity and practicality. We analyze, test, develop and accompany our customers through complex change processes – with technical excellence, methodical strength and a clear eye for feasible solutions.
Further information at https://www.bright-group.com/
About AM Pioneers
AM Pioneers was founded in 2021 with the aim of supporting manufacturing companies in the implementation of 3D printing technologies in the existing manufacturing environment. Today, rapid technological development enables companies to replace conventional manufacturing processes with additive manufacturing processes, starting with the process-related revision of components and extending through the selection of the appropriate process to the implementation of a printing system from Desktop Metal, 3D Ceram and Boston Micro Fabrication (BMF). Further information at www.am-pioneers.com
About BMF – Boston Micro Fabrication
Boston Micro Fabrication (BMF) enables high-precision 3D printing of micro-scale components used in industries such as healthcare, life sciences, electronics and mechanical engineering. Using the company’s proprietary PμSL (projection micro stereolithography) technology, the microArch system printers produce very accurate and precise high-resolution 3D prints for product development, research and small-scale industrial production. BMF was founded in 2016 and has offices in Boston, Shenzhen, Chongqing and Tokyo. For more information about BMF, please visit www.bmf3d.com or follow the company on LinkedIn (https://www.linkedin.com/company/bostonmicrofab/)
