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.<\/p>\n
This patented technology allows for faster, high-resolution 3D printing across larger build areas by combining different projection lenses with distinct imaging resolutions\u201410 microns and 25 microns\u2014within 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.<\/p>\n
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 (P\u00b5SL) technology.<\/p>\n
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.<\/p>\n
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.<\/p>\n
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\u2019s 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.<\/p>\n