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SLA wall thickness issue for microfluidic channels

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Hi, I created a 3D design for a small microfluidic part using SLA (Clear Resin) with internal channels ~0.4 mm wide and wall thickness around 0.5 mm. The function relies on optical inspection through the walls, so transparency and dimensional accuracy are critical. However, in my first print, the walls came out distorted and slightly bulged, affecting both fit and visual clarity. Has anyone found a reliable minimum wall thickness for such features, or specific design tweaks that reduce distortion in thin, clear SLA parts?

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      Hi, I created a 3D design for a small microfluidic part using SLA (Clear Resin) with internal channels ~0.4 mm wide and wall thickness around 0.5 mm. The function relies on optical inspection through the walls, so transparency and dimensional accuracy are critical. However, in my first print, the walls came out distorted and slightly bulged, affecting both fit and visual clarity. Has anyone found a reliable minimum wall thickness for such features, or specific design tweaks that reduce distortion in thin, clear SLA parts?

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    • c

      I’ve had similar issues with clear resin. At your specs, you are likely hitting limits where the bulging and distortion is caused by light bleed and peel forces. I’d suggest increasing the wall thickness to at least 0.7-0.8 mm. Thinner walls will likely bulge or warp during printing and post-curing. Also, printing your part at an angle (30-45°) will help with distortion by minimizing peel forces. You can also add fillets at the wall bases to reduce stress. For clarity, you can post-process with fine sanding and a clear resin dip. Hope this helps.

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SLA wall thickness issue for microfluidic channels
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