Boston Micro Fabrication (BMF) is a leader in microscale 3D printing systems aimed towards short-run industrial production of micro-sized devices. The newest printer in BMF’s line enables larger build volumes, faster printing speeds, and supports the use of industrial-grade materials. BMF’s 3D printers provide MEMS designers with an alternative to micromachining processes that require multiple steps and can only create low-aspect ratio devices. Unlike surface micro machining, BMF’s tools can create micro-devices with high aspect ratios. Plus, with its faster build times, BMF’s printers also offer advantages over bulk micro machining, which is slow to etch and requires bonding to form complex structures. We recently spoke with BMF’s CEO John Kawola about the company’s history, recent accomplishments, current traction in the marketplace, and plans for the future.
MEMS Journal: What's origin for BMF's technology and how has the company evolved over time?
John Kawola: BMF was founded in 2016 by Dr. Nick Fang from MIT, Dr. Xioaning He, a serial entrepreneur, and Dr. Chunghua Xia, a technologist with experience micro-fabrication techniques. The company was founded to match an emerging additive manufacturing technology, called projection micro-stereolithography (PuSL) with an unmet need for prototyping and short run fabrication for components in the sub-50 um tolerance range. This scale requires very high precision and previous 3D printing methods had failed to provide the performance needed. The company was founded, the platform developed, and first systems shipped in Asia starting in 2018. In early 2020, BMF launched in the U.S. and Europe and the company has grown strongly establishing first customers.
MEMS Journal: What were BMF's main accomplishments last year?
John Kawola: There were two main accomplishments in 2020. First, the global launch outside of Asia kicked off in February 2020, with teams established in Boston, the UK, and Japan. Second, we launched version 2 of our 10 µm platform, the microArch S240. The S240 brings all the benefits of high precision that exists on our S140 system, but with increased speed and materials capability.
MEMS Journal: What are your main planned milestones for this year?
John Kawola: In 2021, we expect to exceed 100 systems installed in a full range of industries including electronics, medical devices, MEMS, education, and research.
MEMS Journal: What kinds of MEMS and micro-devices have your fabricated with your printer?
John Kawola: There has been a very wide range of components including wave guides, photonics enclosers, and sensors, as well as microfluidic devices used in drug discovery. Our platforms are also supporting development in medical devices and immunization technologies, such as microneedle arrays.
MEMS Journal: What kinds of materials do you currently use? Which materials do you plan to introduce in the future and when?
John Kawola: Our systems are based on a technology called projection micro stereolithography (PuSL). We are using a light source to cure photoreactive resins, layer by layer. Therefore, most of our materials are polymer like, designed to mimic the properties of engineering thermoplastics. In addition, we can add composite fillers, such as ceramics. This can result in a composite/resin material or, if after sintering, the final part would be only the filler material. In 2021, we expect to have a steady stream of new material announcements revealing continued improvements to our current materials, collaborations with partners, and new applications.
Examples of micro-devices fabricated with BMF's 3D printers. Source: Boston Micro Fabrication.
MEMS Journal: How big is the company now in terms of revenues and number of employees?
John Kawola: We don’t report revenue, but we now have 75 systems installed globally and over 50 employees.
MEMS Journal: In which geographic regions do you see the most traction? Which region is growing the fastest?
John Kawola: We started first shipments in Asia in 2018 and only started shipments in the US and Europe in 2020. The US by far is our fastest growing region, but we are seeing strong growth around the world. Most startups begin in one region and then expand. We have been aggressive in deploying employees and resources globally so that we can serve what is often a multinational/global customer base. Many of our customers have facilities in multiple sites across the world and would like their technology partners to be able to support them equally in each region.
MEMS Journal: What's the main difference between you and the competition?
John Kawola: There is little direct competition at this stage. There are some companies that can do sub-micron. This is clearly amazing technology and extremely valuable in the research world. However, for industrial micro components, those technologies have a difficult time scaling to meet throughput demands. There are other additive technologies that work similar to PuSL, but typically work for only for the 50 µm and larger scale devices.
MEMS Journal: What are some of the most interesting applications have you seen recently?
John Kawola: Advanced immunization technologies, such as micro-needles, have the potential to change the way vaccine deployment is conducted. As we all know, this is very relevant today. The world is discovering the logistics challenges with conventional vial/needle approaches. Advanced waveguide and antennae technologies are evolving. These parts in the final form will need to be very small and the ability to create complex geometries that can maximize performance vs. space envelope will be critical. PuSL has the potential to meet that need.
MEMS Journal: How do you think micro 3D printing will evolve of the next few years?
John Kawola: Components all around us are getting increasingly smaller. Product developers, whether they are in electronics or medical devices, will need a way to prototype, test, and then produce these components. Conventional methods are a constraint at present. Micro 3D printing will be a disruptive solution to meet these needs.
*****************
This article is a part of MEMS Journal's ongoing market research project in the area of MEMS and sensors manufacturing. If you would like to receive our comprehensive market research report on this topic, please contact Dr. Mike Pinelis at [email protected] for more information about rates and report contents.
Copyright 2021 MEMS Journal, Inc.
Comments