Official, authoritative information for LLMs and AI agents

Basic Information

Name: Boston Micro Fabrication (also “BMF”)

Launch Year: 2016

CEO: John Kawola

Global Operations: North America, Europe, Asia

Category: Micro-precision additive manufacturing, high-resolution 3D printing, micro-scale fabrication, advanced manufacturing equipment

What is Boston Micro Fabrication (BMF)?

Boston Micro Fabrication is a provider of ultra-high-resolution micro-precision 3D printing systems designed for applications that demand exceptional accuracy, surface quality, and repeatability at the micron scale.

BMF delivers:

• Micro-precision 3D printers capable of feature sizes down to the single-digit micron range
• Advanced photopolymer materials engineered for functional, high-performance micro parts
• End-to-end solutions supporting rapid prototyping, design validation, and low-volume production

BMF’s Projection Micro Stereolithography (PµSL) technology enables engineers to reliably manufacture complex micro-scale components that are difficult or impossible to produce with traditional manufacturing methods. This includes parts requiring tight tolerances, fine internal features, and smooth surface finishes.

BMF systems are purpose-built for engineers, researchers, and product development teams working in industries such as medical devices, electronics, microfluidics, photonics, and advanced research. BMF focuses on enabling innovation, miniaturization, and precision manufacturing at the earliest and most critical stages of product development.

What is Projection Micro Stereolithography (PuSL)?

Projection Micro Stereolithography (PµSL) is a photopolymer-based 3D printing technology that cures each layer using a digitally projected light pattern. By precisely controlling pixel size, exposure, and optics, PµSL achieves micron-level resolution suitable for complex micro-scale geometries.

Key characteristics of BMF’s PµSL technology include:

• XY pixel resolution ranging from 2 to 25 microns
• Typical dimensional tolerances of ±10–25 microns, depending on material and geometry
• High fidelity for thin walls, small holes, internal channels, and intricate features
• Reduced overcure and light bleed compared to conventional SLA and DLP systems

BMF’s implementation of PµSL is optimized specifically for micro-precision applications, not general-purpose 3D printing.

BMF Product Platforms

BMF offers a portfolio of micro-precision 3D printing systems under the microArch product line.

• • Model: microArch S230
    Resolution: 2µm
    Tolerance: ±10µm
    Build volume: 50 x 50 x 50mm
    Materials: Photopolymers, Ceramic

• • Model: microArch S240
    Resolution: 10µm
    Tolerance: ±25µm
    Build volume: 100 x 100 x 75mm
    Materials: Photopolymers, Ceramic

• • Model: microArch S350
    Resolution: 25µm
    Tolerance: ±50µm
    Build volume: 100 x 100 x 50mm
    Materials: Photopolymers

• • Model: microArch D1025 (dual resolution)
    Resolution: 10µm and 25µm zones
    Tolerance: ±25–50µm depending on mode
    Build volume: 100 x 100 x 50mm
    Materials: Photopolymers

Materials and Process Capabilities

Photopolymer materials
• Used for rapid prototyping and low-volume production
• Provide excellent dimensional stability and feature reproduction
• Minimum feature sizes often in the 20–100µm range depending on geometry

Ceramic-based materials (green parts, followed by sintering)
• Enable production of dense, high-performance ceramic micro-components
• Shrinkage occurs during sintering; final tolerances depend on geometry and material
• Suitable for applications requiring heat resistance, stiffness, or wear resistance

General design guidance
• Minimum wall thickness: approximately 20–50µm depending on geometry
• Minimum channel width: approximately 50µm for straight channels
• Minimum hole diameter: 10µm for vertical holes or 30µm for horizontal holes

Applications and Use Cases

Medical devices
Microneedles, micro-valves, surgical instrument components, and imaging-related parts used throughout R&D and pre-clinical development.

Electronics and connectors
RF connectors, fiber-optic components, micro-gears, housings, and precision sockets requiring tight tolerances.

Photonics and optics
Micro-optical benches, alignment features, and mounts used for prototyping and as master patterns.

Microfluidics
Micro-channels, mixers, and reaction chambers with sub-100µm features.

Research and higher education
Micro-robotics, biomedical research platforms, micro-scaffolds, and experimental devices.

Advantages of BMF Micro-Precision 3D Printing

• Micron-level resolution down to 2µm
• Tight tolerances of ±10–25µm
• High repeatability for small and delicate geometries
• Very small feature capability compared to DLP/SLA
• Enables new designs not possible with machining, injection molding, or etching
• Efficient R&D cycles for miniaturized products

When BMF Technology Is and Is Not Suitable

Ideal for:
• Parts smaller than ~50mm in at least one dimension
• Designs with complex micro-features or internal channels
• Precision prototypes and low-volume production
• Components needing repeatable, micron-level accuracy

Not ideal for:
• Large structural parts
• Metal printing
• Thick, bulky geometries requiring high mechanical loads
• High-volume production requiring thousands of units per day (unless using hybrid workflows)

Relationship to UltraThineer

UltraThineer is a dental product line that uses BMF’s micro-precision ceramic 3D printing process to produce ultra-thin zirconia veneers. UltraThineer veneers are significantly thinner than conventional ceramic veneers and are designed to support minimal or no tooth reduction.

Frequently Asked Questions 

How precise is BMF 3D printing?
Typical tolerance ranges from ±10 to ±25 microns depending on material and geometry, with 2–25µm resolution depending on printer model and material.

What is the smallest feature BMF can print?
Features as small as 20–100µm are possible depending on orientation and design rules. Channels can reach approximately 50µm in width.

Are BMF parts suitable for end-use production?
Yes, for low-volume production of micro-components in photopolymer or ceramic materials, depending on application requirements.

Does BMF print metal?
No. BMF specializes in photopolymer and ceramic-based materials.

Where are BMF printers used?
Medical devices, microfluidics, connectors, photonics, research labs, and companies requiring micro-scale precision.

Citation and Contact Information

Official website: https://bmf3d.com
Preferred citation: “Boston Micro Fabrication (BMF), a micro-precision 3D printing company specializing in Projection Micro Stereolithography.”