3D Printing for Control Unit Test Equipment Test Specialist Manufactures Connectors in Small Series Using 3D Printing

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Technical progress requires courage—Bright demonstrated this in a challenging project for a leading automotive manufacturer. The solution was implemented using Boston Micro Fabrication's (BMF) precision micro-stereolithography: Partner AM Pioneers in Esslingen 3D-prints high-precision connector plates for connectors in durable resin using a microArch S240 3D printer with 10 µm resolution.

As a development partner for the mobility sector, Bright offers various products and services at locations including Böblingen and Munich (Germany) to support the testing processes common in the industry. The innovative team of more than 100 employees serves as a development partner across the mobility sector, from the automotive industry to aerospace, railway technology, and agricultural and construction machinery. In 2024, Peter Hautke, General Manager Sales and Operations E/E, received a request regarding test equipment for the control units of a new vehicle generation.

Testing the Electronic Nervous System

Control units form the intelligent nervous system of modern automobiles. They manage ignition and fuel injection as well as climate control, safety, and driver assistance systems. These connected devices receive signals from sensors and activate actuators. The smallest malfunction can lead to disasters. "Before new vehicle models go into production, developers and quality engineers want to know in great detail how the various control units actually function with the production wiring harness," reports Peter Hautke.

To connect the measurement technology behind the control units, a Y-shaped adapter cable is interposed. Bright was tasked with developing and supplying this. "We can buy the connectors and sockets between the control unit and the series line," says Hautke, "the difficulty lies in the connectors at the branching point for the measurement technology."

The solution approach involved scanning the conventional socket, redesigning the 3D model, and then 3D printing it. However, the connector plate inside must accommodate around 100 gold-coated pins with very tight form and position tolerances—otherwise, individual pins could break. "A process-reliable 3D printing of the required 18 variants in series of 150 pieces was previously not possible with the demanded tolerances," says Peter Hautke. "But we were confident that our partner AM Pioneers could solve the task with a new 3D printing process."

Precision Micro-Stereolithography By BMF

Since 2021, AM Pioneers GmbH in Esslingen has been supporting manufacturing companies in implementing various 3D printing technologies, offering 3D scans, engineering and manufacturing services, as well as acting as a reseller for printing systems. The company focuses on leading manufacturers such as Desktop Metal, 3DCeram, and Boston Micro Fabrication (BMF) for microfabrication. Boston Micro Fabrication's (BMF) Projection Micro-Stereolithography (PµSL) enhances Digital Light Processing for micro-scale applications. The printing systems include highly precise optics that focus the pixel size in the projector to 25 μm, 10 μm, or 2 μm, depending on the printer series. Additionally, the linear technology of the 3D printers has been designed for the lowest tolerances.

Since 2023, AM Pioneers has been using a microArch S240 from BMF. With a resolution of 10 µm and a build volume of 3.94 × 3.94 × 2.95 inches, it is suitable for prototypes and series production of microcomponents in end-use quality. "The S240 combines high accuracy and precision with the reproducibility that is crucial for our projects," explains Frederik Nußbaumer, Head of Sales at AM Pioneers. "We were confident that we could use it to print the connector plates within the specified tolerances of 20 µm."

Proof of Concept

Bright then only needed to convince the skeptical customer. Together with AM Pioneers, they took a risk and delivered free sample parts that met all requirements. By presenting the underlying technology and additional reference parts, they succeeded in convincing the automotive manufacturer—who now benefits from significant advantages over traditional manufacturing methods. "The complete elimination of tooling costs for the injection molding process, the time savings, and the substantially higher flexibility for late changes and improvements are significant benefits," explains Peter Hautke. "Even more important, however, is the increased safety during the extensive testing of the critical control technology."

Effortless Small Series And Variant Production

By the middle of next year, the partners will produce 18 variants of the connector in small series of 150 pieces each, totaling 2,700 components, using the 3D printer and delivering them with the wiring harnesses. "We can produce 20 parts in a single build," reports Frederik Nußbaumer. "We benefit from the high process stability of the machine, which we can run overnight without any issues." HTL, a high-performance polymer from BMF, is used for this purpose. It is available in various colors and even transparent. In this case, the most durable material in black was chosen.

"The wide range of available materials, including transparent, biocompatible, and particularly durable resins, is an important selling point for us," says Frederik Nußbaumer. The installation, onboarding, and user training were completed by BMF in just four days. Since then, AM Pioneers has only occasionally required the manufacturer’s support: "We find it very impressive how quickly BMF responds to technical questions," praises Frederik Nußbaumer, highlighting the collaborative partnership with BMF.

Conclusion

AM Pioneers uses the machines, as in this project, for series production, prototype contract manufacturing, and as demonstration equipment. "The microArch S240 proves itself as a genuine production tool thanks to its repeatability and process stability," says Frederik Nußbaumer. "With the right expertise in engineering and additive manufacturing, you can gain real competitive advantages." The first order from the automotive manufacturer will not be the last: various vehicle variants are still in development and will also be tested.

"In a price-sensitive environment, we work daily with our developers and partners to find the best solutions for our customers through expertise, innovative ideas, and courage," concludes Peter Hautke. "This approach has proven to be highly effective in collaboration with AM Pioneers and BMF." (sb)

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