Boston Micro Fabrication (BMF), a leader in micro-precision 3D printing, has announced the granting of a significant U.S. patent for its innovative dual-resolution micro-scale 3D printing technology. The U.S. Patent No. 12,420,486 B2, titled "Multi-Scale System for Projection Micro Stereolithography," is pivotal to the company’s microArch D1025 printer.
This patented technology allows for faster, high-resolution 3D printing across larger build areas by combining different projection lenses with distinct imaging resolutions—10 microns and 25 microns—within a single optical path. The flexibility of this dual-lens design enables the printer to switch between resolutions dynamically, optimizing detail and speed without sacrificing precision.
CEO John Kawola emphasized that this patent solidifies BMF’s position in ultra-high-precision additive manufacturing. The dual-resolution feature allows engineers to produce micro components with intricate details alongside larger geometries in a single print, representing a significant advancement in Projection Micro Stereolithography (PµSL) technology.
The innovation has promising implications for industries such as medical devices, electronics, microfluidics, and research, enabling consistent micron-level accuracy across complex geometries. The system can automatically allocate finer exposures for critical features while using coarser exposures for larger areas, resulting in quicker builds without compromising on quality.
The microArch D1025, which launched in 2024, is the first commercial system to incorporate the patented dual-resolution capability, catering specifically to the needs of medical device and electronics manufacturers who seek both precision and efficiency in production.
The patent was issued on September 23, 2025, and was co-invented by Dr. Chunguang Xia and Dr. Jiawen Xu, assigned to BMF Material Technology Inc., BMF’s parent company based in Shenzhen, China. Dr. Xia, also the company’s Co-Founder and Chief Technology Officer, noted that the microArch D1025 is not merely a significant optical innovation, but a platform that is meant to revolutionize micro-fabrication.
For further details, visit BMF.