Stereolithography LED–LCD 3-D Printing With Sub-5 Micron Layer Thickness

This letter presents a comprehensive study on the enhancement of layer thickness resolution in stereolithography apparatus (SLA) 3-D printing, with a focus on its application in microfluidics. The study explores the potential of SLA 3-D printing to compete with soft lithography by achieving layer thicknesses below 5 μm. We describe an experimental setup involving a custom-built LED–LCD 3-D printer with a feedback system for improved positioning accuracy. The results demonstrate a significant improvement in the positioning accuracy along the
Z
-axis (vertical) below 1.5 μm, with layer thicknesses as low as 2 μm achieved. Comparisons with a commercial 3-D printer highlight the superior performance of the custom-built printer. This letter also presents an analysis of the results, discussing the implications and potential applications in microfluidics. The findings of this study pave the way for the broader use of SLA 3-D printing in the fabrication of microfluidic devices, potentially surpassing the capabilities of soft lithography.