Boston Micro Fabrication (BMF) has introduced BMF Clear, a new optically transparent photopolymer resin developed specifically to meet the requirements of micro-precision 3D printing. The material is intended for applications such as microfluidics, photonics, optical components, and biomedical devices—in other words, wherever both light transmission and dimensional accuracy in the micrometer range are required.

With a light transmission of over 90 percent, BMF Clear fills a gap that has long existed in the industry: Until now, developers of transparent 3D printing materials have had to compromise either on optical quality or on print resolution. Especially at the micro level, material absorption and surface roughness regularly cause light scattering, thereby limiting the material’s applicability. BMF Clear is designed to address both issues—through an excellent surface finish that minimizes scattering and through its integration into the company’s proven projection microstereolithography (PµSL) technology.

The material is designed for BMF’s 10- and 25-micrometer systems and processes layer heights between 10 and 50 micrometers. It is compatible with the entire BMF platform, from high-end systems to the compact desktop model, the microArch S150. The high printing resolution ensures fine structures and smooth surfaces, which reduces light scattering and improves transmission through internal channels. A practical side effect: the amount of post-processing required is significantly reduced.

Overview of Areas of Application

Specifically, the material opens up new possibilities, for example, in microfluidic lab-on-a-chip systems with channels for fiber alignment, in free-form microlenses printed directly onto glass fiber tips or sensor arrays, and in integrated waveguides for sensor technology and data communication. Processes such as cell culture or the generation of high-resolution droplets benefit particularly from the precise visualization provided by optically clear, flow-permeable channels.

The material also offers potential in the fields of micro-optics and integrated photonics: fiber-to-chip couplers, complex microstructures for high-speed data communication, and imaging systems can all be manufactured in a single step using this material.

For biomedical applications, BMF Clear has also undergone rigorous biocompatibility testing, including tests for skin irritation, sensitization, and in vitro cytotoxicity. This qualifies the material for use in endoscopic systems, intraocular instruments, and minimally invasive drug delivery systems. In addition, it is suitable for optical waveguides, spectroscopy components, and integrated flow cells for UV/Vis or fluorescence analysis.