High precision and micro 3D printing—until now, these two concepts have been inseparable. Anyone requiring resolutions in the single-micrometer range inevitably had to work with extremely small components. Boston Micro Fabrication (BMF) has defined precisely this market since its global market entry in 2020: Using its patented PµSL (Projection Micro Stereolithography) technology, the company has produced 3D-printed microcomponents in a quality previously reserved exclusively for micro-injection molding and CNC micro-milling.

The industry needs more than just Microcomponents

Boston Micro Fabrication’s micro 3D printing has opened up new possibilities for industries such as medical technology, electronics, optics, and biopharmaceuticals: delicate, high-resolution components with resolutions of up to 2 µm and tolerances of ±10–25 µm—produced without tools, in hours rather than weeks.

At the same time, discussions with users and industry partners revealed a growing need: Many companies require not only microcomponents, but also larger components with the same precision and surface quality they have come to expect from micro 3D printing. From electronics and medical technology to the consumer goods industry, development teams were looking for a process that combines both—larger component dimensions and micrometer-level dimensional accuracy.

Traditional manufacturing processes have not been able to deliver this combination until now: either the parts were large enough but lacked sufficient precision—or the precision was there, but the build volumes were too small. Boston Micro Fabrication recognized this unmet need and made it the starting point for a strategic expansion.

The technological leap: From micro 3D printing to scalable high precision

Expanding from purely micro 3D printing to larger components was no small feat. It wasn’t enough to simply increase the build volume—the entire process chain had to be reimagined: optics, motion control, software algorithms, and materials science.

Boston Micro Fabrication has made significant investments in research and development to create platforms that combine precision, scalability, and flexibility. The result is two systems that take micro 3D printing to a new level: the microArch D1025 and the microArch S150 Series.

The microArch D1025 is the world’s first dual-resolution system for micro 3D printing. It prints at either 10 µm or 25 µm resolution—or combines both resolutions within a single print job in hybrid mode. With this, Boston Micro Fabrication solves a key problem faced by many users: Components that require extremely fine microstructures in certain areas and larger geometries in other zones previously had to be printed on two different systems. The D1025 combines this into a single platform—with a build volume of 100 × 100 × 50 mm and integrated automation for small-batch production.

The microArch S150 Series takes a different approach: it brings Boston Micro Fabrication’s micro 3D printing technology into a compact desktop format with 25 µm resolution and one-touch operation. The S150 Series lowers the barrier to entry for laboratories, research institutes, and development teams that require high-precision components without the space requirements and complexity of larger industrial systems. The S150 Ultra is also available as a high-speed variant that prints up to 9× faster than the standard S150.

What this means for users

With the D1025 and the S150 Series, Boston Micro Fabrication is significantly expanding the range of applications for micro 3D printing. Users now have access to platforms tailored precisely to their needs—whether that means maximum flexibility through dual resolution or a compact, straightforward entry into micro 3D printing.

Specifically, this means that a connector housing with fine contact structures and larger mounting surfaces can be manufactured in a single print job on the D1025 in hybrid mode—with fine areas at 10 µm and coarser areas at 25 µm. A research team that needs functional microprototypes quickly can print directly at their workstations using the S150 Series, without having to rely on a central printing lab.

Boston Micro Fabrication’s message is clear: high precision is no longer a matter of component size—nor is it a matter of system complexity. Micro 3D printing is becoming more accessible, flexible, and production-ready than ever before.

Boston Micro Fabrication in the DACH region

As an authorized Boston Micro Fabrication dealer in Germany, we can advise you on all microArch systems—from the S230 with 2 µm resolution for traditional micro 3D printing, to the D1025 with dual resolution, to the compact S150 Series for entry-level users. We help you find the right platform for your application—from feasibility analysis and benchmark components to system integration.

Are you interested in evaluating micro 3D printing or high-precision additive manufacturing for your application? We can help you find the right solution. Contact us for a consultation or a free benchmark component.

Erik Nitsche
Sales Engineer BMF
+49 162 764 2630
erik.nitsche@am-pioneers.com