The demand for high-precision, small-scale, customizable components is increasing as technologies get smaller and more complex. At times, traditional manufacturing methods struggle to keep up. This can lead to long lead times, high costs and inflexible designs.
As an alternative, scientists and research institutions have turned to 3D printing, which offers a more agile, cost-effective solution. Where methods like microinjection molding can take 10 to 12 weeks for critical components, 3D printing bypasses typical bottlenecks to offer faster timelines and more flexibility in design.
For example, researchers at UNC’s Department of Biomedical Engineering employed 3D printing in their quest to create a microneedle-based colorimetric pH sensing patch for dual applications: monitoring food quality and assessing wound health.
The team used Boston Micro Fabrication’s 3D printer to produce parts with resolutions ranging from 2 to 25 microns using projection micro-stereolithography (PµSL) technology, enabling the creation of intricate and exact microneedle devices.
Subsequent in vitro results demonstrated the effectiveness of the pH sensing patch. The data confirmed that the patch could be successfully used for both wound pH monitoring and meat spoilage detection. The patch offers a practical solution for ensuring food safety and enhancing wound care management, thereby improving overall health outcomes.
Precision and repeatability
The same PµSL technology is built into Boston Micro Fabrication’s newest 3D printer—the microArch D1025. The micro 3D printer is the first to provide dual resolution (10 or 25 µm) 3D printing capabilities for micro-scale, ultra-high resolution and precision applications across healthcare, electronics, medical devices, life sciences and photonics.
Using a technique that allows for rapid photopolymerization of layers of liquid polymer using a flash of UV light at micro-scale resolution, the 25 µm resolution mode can be used for parts in which the features don’t require ultra-high resolution. Meanwhile,10 µm mode supports small, complex features to optimize the 3D printing process. Users also have the ability to choose to print a single build in either 25 µm or 10 µm depending upon the part geometry, providing greater flexibility and efficiency across all applications and industries.
In addition to offering dual platform capabilities, the microArch D1025 delivers enhanced, built-in automation. For example, print settings for roller frequency and resin leveling delay times are automatically set according to the printing area and material viscosity when using automatic mode. However, users still have full manual control, if desired.
Ultimately, the microArch D1025 enables greater efficiency, saving time, resources and cost. Delivering ultra-high resolution and accuracy, the 3D printer brings micron-level precision and repeatability to scientists across healthcare, electronics, medical devices, life sciences and photonics.