ULTRA-HIGH RESOLUTION, ACCURACY, AND PRECISION

Advanced Additive Manufacturing Solutions

Boston Micro Fabrication is the world leader in advanced additive manufacturing solutions based on Projection Micro Stereolithography (PµSL) technology. Many leading companies worldwide are adopting PµSL to 3D print true microstructures with ultra-high printing resolution (2µm~50µm) and printing tolerance (+/- 10µm ~ +/- 25µm).

Micro-precision 3D printing is the optimal manufacturing process for various use cases across a wide variety of industries. BMF empowers companies with complete design freedom to enable the creation of geometries that can be manufactured no other way. The combination of ultra-high resolution, accuracy, and precision allows for more intricate, exact, and replicable parts, at scale and tolerances that match those of micro injection molded parts.

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News

Introducing the microArch D1025

Introducing the first 3D printer in BMF’s Dual Resolution Series – the microArch D1025! The microArch D1025 features dual-resolution functionality, capable of printing at either 10µm or 25µm, or switching between 10µm and 25µm within the same build.

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Our Capabilities

MICROFLUIDICS

MICROFLUIDIC CHIP

  • Tolerance=±0.025mm;
  • Part Size: 15mm x35mm x6.2mm
  • Integrated forming
  • Complex internal channels
  • Minimum flow path of 400µm
  • Resolution: 10μm
ELECTRONICS

CHIP ARRAY SOCKET

  • Tolerance=±0.025mm;
  • Mirror finish, sharp edges, heat resistant
  • 2100 micro holes with a diameter of .35mm and spacing of 50µm
  • Resolution: 10μm
ELECTRONICS

ELECTRONIC CONNECTOR

  • Tolerance=±0.025mm;
  • Part Size: 10.83mm ×4.33mm x2.9mm
  • 140um slots and walls
  • Resolution: 10μm
Medical Devices

Endoscope Shell

  • Tolerance=±0.025mm;
  • Part Size: 9.8mm x 9.8mm x 13.8mm
  • Tube diameter = 1.2mm, length = 4mm, minimum wall thickness = 65 um
  • Several types of complex structures are included
  • Resolution: 10μm

Applications

3D Printing a Ureteroscope Endcap

A ureteroscope is a flexible medical device designed to access the kidney and urinary system for diagnosis and treatment. At the heart of this innovation lies a key component: the endcap, where a camera sensor, fiber-optic illumination, and multiple working channels for tools and irrigation need to come together seamlessly.

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Our Products

Build Size

Layer Thickness

Optical Resolution

Printing Material
Clear Filters
microArch® D1025
microArch® S140
microArch® S230
microArch® S240
microArch® S350

Customer Story

3D Printed High-Heat Resistant Connectors for Soldering

BMF’s technology enabled Z-Axis to transition towards surface mount components, eliminating the need for through-hole accommodations. This not only enhanced the efficiency of electronic assemblies but also allowed for more compact designs, saving valuable board real estate and meeting the demands of modern electronics.

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Request a Benchmark Part

We’d be happy to manufacture a benchmark part so you can assess our quality.

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Customer Story

Micro 3D Printing for Disposable Medical Devices

Learn how RNDR Medical developed a novel single-use scope for endourology using BMF’s microArch platform.

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The quality and accuracy of BMF PµSL parts is very unique, and truly mimic expensive micro molded parts, and now we can have parts ready for test within 1-2 days rather than 1-2 months, as well as reducing the huge costs associated with tooling manufacture and reworking as the new products evolve. We can also explore designs previously out of reach due to manufacturing limitations. Our main focus is to lift our prototyping capabilities to the highest possible level, both in quality and speed. BMF will help us accomplish that.

– Sally van der Most, DSS Manager, Sonion NL

We chose BMF’s microArch 3D Printer due to its ability to replicate critical micro features. Their unique Projection Micro Stereolithography (PµSL) technology prints 3D parts with ultra-high resolution and accuracy, which is key to our business. This is the first 3D printer we’ve encountered that can print micro-precision parts, with the dimensional accuracy and precision that our customers require at this stage of product development. We have put the BMF parts through the same rigorous CT scanning inspection process of our micro molded components and were amazed that dimensionally the parts fell within the tolerances required. Our customers have been equally amazed.

– Donna Bibber, VP of Business Development, Isometric Micro Molding, Inc.

We have been looking for some time for a machine that can reliably produce parts in this size range as we were at the limits of other machines or would have to sink cost into other manufacturing methods- typical micro injection molding or other micro machining activity that can be expensive and prohibitive to R&D iterations. The ability to rapidly produce these types of parts combined with an open ecosystem is unmatched.

– Sam Wilson, STORM Lab UK, Institute of Robotics and Autonomous Sensing, University of Leeds

As one of BMF’s first customers, we’ve been excited by the performance of their high-resolution 3D printing solution. Most recently we have been evaluating BMF’s first-generation microArch P150, and it has delivered accuracy that is not attainable by any other system we have used within our additive lab. With its high part quality and throughput suitable for production, as well as the ability to print a wider variety of materials, the microArch S350 has become a critical tool in printing high-resolution connectors,” said Xiaoming Luo, Principal 3D Printing Engineer, Aerospace, Defense, and Marine (AD&M) at TE Connectivity. “We feel the microArch S350 gives TE the ability to produce very high resolution connectors for our customers.

– Xiaoming Luo, Principal 3D Printing Engineer, Aerospace, Defense, and Marine (AD&M) at TE Connectivity

June 5, 2025 • Laboratory News

3D Printing in the Lab

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June 5, 2025 • Select Science

Micro-3D Printing Powers Cancer Organoid Research

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