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In this work, five transparent masked stereolithography resins employed in an Anycubic Photon M7 Pro low-cost printer are systematically studied to address the limitations mentioned above. The working route was based on the analysis of the dimensions of negative and positive microfeatures, their transmission spectra, their cytotoxicity, the capability of building internal channels, replicability in PDMS, and validation by computational fluid dynamics simulations with experimental fluid assays. Resolution tests revealed that negative structures resolved less accurately due to subtle resin accumulation during the layer-by-layer printing process. Internal channel fabrication showed a practical lower limit of approximately 500 \u03bcm under the printing and postprocessing conditions used in the study, with resin viscosity, printing angle, and drainage behavior strongly influencing channel clearance. The Standard V2 and High Clear resins exhibited the highest printing resolution with microchannels printed in a vertical or almost-vertical position. Regarding thermally cured PDMS replication, the Tough Ultra, ABS-like Pro 2, and Water-Wash were the ones exhibiting the most accurate outcome. From a biological point of view, all resins were non-cytotoxic, with Standard V2 and High Clear exhibiting the highest cell viability, in some cases better than the control scenario. Contact angle measurements indicated that the Standard V2 and High Clear resins are highly hydrophilic, whereas the remaining resins exhibit a hydrophobic behavior. Swelling was found to be dependent on the media, where the Water-Wash found high swelling in Milli-Q water and PBS and the Tough Ultra in ethanol. Samples were only minimally affected by isopropyl alcohol. Finally, fluid flow assays were conducted on three different microfluidic chips to demonstrate that the introduction of microfeatures and zigzag architectures fosters the disruption of laminar flow conditions by introducing secondary flows and vorticity to mimic more physiological environments. These experiments were contrasted with simulations performed by computational fluid dynamics. It was verified that microfeatures can be adequately implemented in the chip architecture and result in enhanced mixing. This validation allowed defining a practical operating window for MSLA 3D printers for microfluidics.<\/jats:p>","DOI":"10.1021\/acsomega.6c02218","type":"journal-article","created":{"date-parts":[[2026,8,12]],"date-time":"2026-08-12T16:03:18Z","timestamp":1786550598000},"page":"49310-49329","source":"Crossref","is-referenced-by-count":0,"title":["Defining Operational\nLimits of Low-Cost MSLA 3D Printing\nfor Microfluidic Systems: Resin Performance, Cell Compatibility, and\nFluid Dynamics"],"prefix":"10.1021","volume":"11","author":[{"given":"Yago","family":"Radziunas-Salinas","sequence":"first","affiliation":[{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]},{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-5050-9663","authenticated-orcid":true,"given":"Ba\u0301rbara","family":"Blanco-Ferna\u0301ndez","sequence":"additional","affiliation":[{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]},{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, E-15782"]},{"name":"Complexo Hospitalario Universitario de Santiago de Compostela , , Travesa da Choupana s\/n. , ,","place":["Santiago de Compostela, Spain, 15706"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Vanessa","family":"Valdiglesias","sequence":"additional","affiliation":[{"name":"Universidade da Corun\u0303a , ,","place":["A Corun\u0303a, Spain, 15071"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-8036-9654","authenticated-orcid":true,"given":"Mari\u0301a Teresa","family":"Flores-Arias","sequence":"additional","affiliation":[{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]},{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-0602-800X","authenticated-orcid":true,"given":"Carmen","family":"Bao-Varela","sequence":"additional","affiliation":[{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]},{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8191-0257","authenticated-orcid":true,"given":"Ana Isabel","family":"Go\u0301mez-Varela","sequence":"additional","affiliation":[{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]},{"name":"Universidade de Santiago de Compostela , , ,","place":["Santiago de Compostela, Spain, 15782"]}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"316","published-online":{"date-parts":[[2026,8,12]]},"reference":[{"issue":"1","key":"2026083119142414700_cit1","doi-asserted-by":"publisher","first-page":"19","DOI":"10.1039\/b211429a","article-title":"Measurement of Density\nand Chemical Concentration Using a Microfluidic Chip","volume":"3","author":"Sparks","year":"2003","journal-title":"Lab Chip"},{"issue":"8","key":"2026083119142414700_cit2","doi-asserted-by":"publisher","first-page":"2280","DOI":"10.1039\/D3LC00822C","article-title":"High-Throughput 3D Microfluidic Chip\nfor Generation of Concentration Gradients and Mixture Combinations","volume":"24","author":"Zhao","year":"2024","journal-title":"Lab Chip"},{"issue":"4","key":"2026083119142414700_cit3","doi-asserted-by":"publisher","first-page":"5563","DOI":"10.1021\/acsami.4c20455","article-title":"Engineered Cell Microenvironments: A Benchmark Tool\nfor Radiobiology","volume":"17","author":"Akolawala","year":"2025","journal-title":"ACS Appl. 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Nanofluidics"},{"issue":"1","key":"2026083119142414700_cit7","doi-asserted-by":"publisher","first-page":"210","DOI":"10.1039\/C3LC50878A","article-title":"SU-8 Bonding Protocol\nfor the Fabrication of Microfluidic\nDevices Dedicated to FTIR Microspectroscopy of Live Cells","volume":"14","author":"Mitri","year":"2014","journal-title":"Lab Chip"},{"issue":"2","key":"2026083119142414700_cit8","doi-asserted-by":"publisher","first-page":"408","DOI":"10.1016\/j.sna.2005.01.012","article-title":"Free-Standing SU-8 Microfluidic Chips by Adhesive Bonding\nand Release Etching","volume":"120","author":"Tuomikoski","year":"2005","journal-title":"Sens. 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Nano Mater."},{"issue":"1","key":"2026083119142414700_cit13","doi-asserted-by":"publisher","first-page":"50","DOI":"10.1038\/s41378-021-00277-8","article-title":"Tumor-on-a-Chip: From Bioinspired Design to Biomedical Application","volume":"7","author":"Liu","year":"2021","journal-title":"Microsyst. Nanoeng."},{"issue":"8","key":"2026083119142414700_cit14","doi-asserted-by":"publisher","first-page":"731","DOI":"10.3390\/mi11080731","article-title":"Rapid Fabrication\nof Membrane-Integrated\nThermoplastic Elastomer Microfluidic Devices","volume":"11","author":"McMillan","year":"2020","journal-title":"Micromachines"},{"issue":"5","key":"2026083119142414700_cit15","doi-asserted-by":"publisher","first-page":"051502","DOI":"10.1063\/1.4998604","article-title":"Advances\nin Microfluidic Devices\nMade from Thermoplastics Used in Cell Biology and Analyses","volume":"11","author":"Gencturk","year":"2017","journal-title":"Biomicrofluidics"},{"issue":"1","key":"2026083119142414700_cit16","doi-asserted-by":"publisher","first-page":"17646","DOI":"10.1038\/s41598-024-68761-5","article-title":"Rapid Prototyping\nof Thermoplastic Microfluidic Devices via SLA 3D Printing","volume":"14","author":"Khoo","year":"2024","journal-title":"Sci. Rep."},{"issue":"1","key":"2026083119142414700_cit17","doi-asserted-by":"publisher","first-page":"150","DOI":"10.1021\/acs.analchem.9b04986","article-title":"Microfluidics: Innovations\nin Materials and Their Fabrication\nand Functionalization","volume":"92","author":"Nielsen","year":"2020","journal-title":"Anal. Chem."},{"issue":"1","key":"2026083119142414700_cit18","doi-asserted-by":"publisher","first-page":"28793","DOI":"10.1038\/s41598-024-80332-2","article-title":"Microfluidics\nChips Fabrication Techniques\nComparison","volume":"14","author":"Liu","year":"2024","journal-title":"Sci. Rep."},{"issue":"1","key":"2026083119142414700_cit19","doi-asserted-by":"publisher","first-page":"20215","DOI":"10.1038\/s41598-019-56711-5","article-title":"Maskless,\nrapid manufacturing of\nglass microfluidic devices using a picosecond pulsed laser","volume":"9","author":"Wlodarczyk","year":"2019","journal-title":"Sci. Rep."},{"issue":"1","key":"2026083119142414700_cit20","doi-asserted-by":"publisher","first-page":"221","DOI":"10.1080\/17458080.2018.1509382","article-title":"Low-Cost and Facile\nImplementation of Microfluidic Colour-Changing\nDevices Using Dry Film Photoresist-Based Moulds","volume":"13","author":"Zhang","year":"2018","journal-title":"J. Exp. Nanosci."},{"key":"2026083119142414700_cit21","doi-asserted-by":"publisher","first-page":"650","DOI":"10.1016\/j.snb.2018.12.053","article-title":"Rapid and\nLow-Cost Development of Microfluidic Devices Using Wax Printing and\nMicrowave Treatment","volume":"284","author":"Morbioli","year":"2019","journal-title":"Sens. Actuators B Chem."},{"issue":"17","key":"2026083119142414700_cit22","doi-asserted-by":"publisher","first-page":"2899","DOI":"10.1039\/C7LC00644F","article-title":"Custom 3D Printer\nand Resin for 18 \u039cm \u00d7 20 \u039cm Microfluidic Flow Channels","volume":"17","author":"Gong","year":"2017","journal-title":"Lab Chip"},{"issue":"8","key":"2026083119142414700_cit23","doi-asserted-by":"publisher","first-page":"652","DOI":"10.3390\/bios12080652","article-title":"Multi-Resin Masked Stereolithography\n(MSLA) 3D Printing for Rapid and Inexpensive Prototyping of Microfluidic\nChips with Integrated Functional Components","volume":"12","author":"Ahmed","year":"2022","journal-title":"Biosensors"},{"issue":"50","key":"2026083119142414700_cit24","doi-asserted-by":"publisher","first-page":"69807","DOI":"10.1021\/acsami.4c10547","article-title":"Multipath\nProjection Stereolithography for Three-Dimensional Printing Microfluidic\nDevices","volume":"16","author":"Geffert","year":"2024","journal-title":"ACS Appl. Mater. Interfaces"},{"issue":"10","key":"2026083119142414700_cit25","doi-asserted-by":"publisher","first-page":"2774","DOI":"10.1039\/D3LC01125A","article-title":"High-Resolution Low-Cost LCD 3D Printing\nfor Microfluidics and Organ-on-a-Chip Devices","volume":"24","author":"Shafique","year":"2024","journal-title":"Lab Chip"},{"issue":"45","key":"2026083119142414700_cit26","doi-asserted-by":"publisher","first-page":"45537","DOI":"10.1021\/acsomega.4c07776","article-title":"Democratizing\nAccess to Microfluidics: Rapid Prototyping of Open Microchannels with\nLow-Cost LCD 3D Printers","volume":"9","author":"Leong","year":"2024","journal-title":"ACS Omega"},{"issue":"16","key":"2026083119142414700_cit27","doi-asserted-by":"publisher","first-page":"3537","DOI":"10.1039\/D3LC00094J","article-title":"Vat Photopolymerization\n3D Printed Microfluidic Devices for Organ-on-a-Chip Applications","volume":"23","author":"Milton","year":"2023","journal-title":"Lab Chip"},{"key":"2026083119142414700_cit28","doi-asserted-by":"publisher","first-page":"103926","DOI":"10.1016\/j.addma.2023.103926","article-title":"Study of Proximity Effect in Projection Based Micro\nVat Photopolymerization Process","volume":"79","author":"Chivate","year":"2024","journal-title":"Addit. Manuf."},{"issue":"1","key":"2026083119142414700_cit29","doi-asserted-by":"publisher","first-page":"16","DOI":"10.3390\/mi14010016","article-title":"A Solution to the Clearance\nProblem of Sacrificial Material in 3D Printing of Microfluidic Devices","volume":"14","author":"Hornik","year":"2023","journal-title":"Micromachines"},{"issue":"4","key":"2026083119142414700_cit30","doi-asserted-by":"publisher","first-page":"1243","DOI":"10.1038\/s41596-022-00792-6","article-title":"Print\u2013Pause\u2013Print\u2019\nProtocol for 3D Printing Microfluidics Using Multimaterial Stereolithography","volume":"18","author":"Kim","year":"2023","journal-title":"Nat. Protoc."},{"key":"2026083119142414700_cit31","doi-asserted-by":"publisher","first-page":"112388","DOI":"10.1016\/j.msec.2021.112388","article-title":"Microfluidic Devices Manufacturing with a Stereolithographic\nPrinter for Biological Applications","volume":"129","author":"Carnero","year":"2021","journal-title":"Mater.\nSci. Eng. C"},{"issue":"12","key":"2026083119142414700_cit32","doi-asserted-by":"publisher","first-page":"2287","DOI":"10.1039\/C6LC00153J","article-title":"3D-Printing of Transparent\nBio-Microfluidic Devices in PEG-DA","volume":"16","author":"Urrios","year":"2016","journal-title":"Lab Chip"},{"key":"2026083119142414700_cit33","doi-asserted-by":"publisher","first-page":"114254","DOI":"10.1016\/j.matdes.2025.114254","article-title":"Advancements and\nChallenges in SLA-Based Microfluidic\nDevices for Organ-on-Chip Applications","volume":"256","author":"Barbosa","year":"2025","journal-title":"Mater.\nDes."},{"issue":"12","key":"2026083119142414700_cit34","doi-asserted-by":"publisher","first-page":"3536","DOI":"10.1557\/JMR.2001.0485","article-title":"Cure Depth in Photopolymerization:\nExperiments and Theory","volume":"16","author":"Lee","year":"2001","journal-title":"J. Mater. Res."},{"key":"2026083119142414700_cit35","doi-asserted-by":"publisher","DOI":"10.1021\/bk-1997-0673","volume-title":"Photopolymerization","author":"Scranton","year":"1997"},{"issue":"13","key":"2026083119142414700_cit36","doi-asserted-by":"publisher","first-page":"3011","DOI":"10.3390\/ma13133011","article-title":"3D Printing of Cell Culture Devices: Assessment and Prevention of\nthe Cytotoxicity of Photopolymers for Stereolithography","volume":"13","author":"Kre\u00df","year":"2020","journal-title":"Materials"},{"key":"2026083119142414700_cit37","doi-asserted-by":"publisher","first-page":"104715","DOI":"10.1016\/j.addma.2025.104715","article-title":"Toxicity of Stereolithography\n3D Printed Objects at the Chemical Level and Strategies to Improve\nBiocompatibility","volume":"101","author":"Tian","year":"2025","journal-title":"Addit. Manuf."},{"key":"2026083119142414700_cit38","doi-asserted-by":"publisher","first-page":"100044","DOI":"10.1016\/j.stlm.2021.100044","article-title":"Biocompatible 3D Printing\nResins for Medical Applications:\nA Review of Marketed Intended Use, Biocompatibility Certification,\nand Post-Processing Guidance","volume":"5","author":"Guttridge","year":"2022","journal-title":"Ann. 3D Print.\nMed."},{"issue":"19","key":"2026083119142414700_cit39","doi-asserted-by":"publisher","first-page":"7180","DOI":"10.1021\/acs.analchem.0c04944","article-title":"PDMS Curing Inhibition on 3D-Printed\nMolds: Why? Also,\nHow to Avoid It?","volume":"93","author":"Venzac","year":"2021","journal-title":"Anal. Chem."},{"issue":"6","key":"2026083119142414700_cit40","doi-asserted-by":"publisher","first-page":"684","DOI":"10.3390\/mi16060684","article-title":"On the Effects\nof 3D Printed Mold Material, Curing Temperature, and Duration on Polydimethylsiloxane\n(PDMS) Curing Characteristics for Lab-on-a-Chip Applications","volume":"16","author":"Mercimek","year":"2025","journal-title":"Micromachines"},{"issue":"9","key":"2026083119142414700_cit41","doi-asserted-by":"publisher","first-page":"2129","DOI":"10.1039\/D4LC00836G","article-title":"Light-Based\n3D Printing and Post-Treatments of Moulds for PDMS Soft Lithography","volume":"25","author":"Venzac","year":"2025","journal-title":"Lab Chip"},{"issue":"13","key":"2026083119142414700_cit42","doi-asserted-by":"publisher","first-page":"1900935","DOI":"10.1002\/pssa.201900935","article-title":"The Liberalization of Microfluidics:\nForm 2 Benchtop 3D Printing as an Affordable Alternative to Established\nManufacturing Methods","volume":"217","author":"Heidt","year":"2020","journal-title":"Phys. Status Solidi"},{"issue":"2","key":"2026083119142414700_cit43","doi-asserted-by":"publisher","first-page":"41","DOI":"10.3390\/fluids10020041","article-title":"The Impact\nof Polydimethylsiloxane (PDMS) in Engineering: Recent Advances and\nApplications","volume":"10","author":"Lima","year":"2025","journal-title":"Fluids"},{"issue":"2","key":"2026083119142414700_cit44","doi-asserted-by":"publisher","first-page":"026502","DOI":"10.1063\/1.3259624","article-title":"Fabrication of Microfluidic Devices Using Polydimethylsiloxane","volume":"4","author":"Friend","year":"2010","journal-title":"Biomicrofluidics"},{"issue":"27","key":"2026083119142414700_cit45","doi-asserted-by":"publisher","first-page":"48958","DOI":"10.1002\/app.48958","article-title":"PDMS Microfluidics:\nA Mini Review","volume":"137","author":"Raj","year":"2020","journal-title":"J. Appl. Polym. Sci."},{"issue":"3","key":"2026083119142414700_cit46","doi-asserted-by":"publisher","first-page":"035017","DOI":"10.1088\/0960-1317\/24\/3\/035017","article-title":"Mechanical Characterization\nof Bulk Sylgard 184 for Microfluidics and Microengineering","volume":"24","author":"Johnston","year":"2014","journal-title":"J. Micromech. Microeng."},{"issue":"10","key":"2026083119142414700_cit47","doi-asserted-by":"publisher","first-page":"107001","DOI":"10.1088\/1361-6439\/ab341e","article-title":"On-Ratio PDMS Bonding\nfor Multilayer Microfluidic Device Fabrication","volume":"29","author":"Lai","year":"2019","journal-title":"J. Micromech. Microeng."},{"issue":"28","key":"2026083119142414700_cit48","doi-asserted-by":"publisher","first-page":"30281","DOI":"10.1021\/acsomega.4c01148","article-title":"Biocompatibility Testing of UV-Curable Polydimethylsiloxane\nfor Human Umbilical Vein Endothelial Cell Culture on-a-Chip","volume":"9","author":"Go\u0301mez-Varela","year":"2024","journal-title":"ACS Omega"},{"issue":"1","key":"2026083119142414700_cit49","doi-asserted-by":"publisher","first-page":"62","DOI":"10.1038\/s41378-022-00386-y","article-title":"Geometric Structure\nDesign of Passive Label-Free Microfluidic Systems for Biological Micro-Object\nSeparation","volume":"8","author":"Tang","year":"2022","journal-title":"Microsyst. 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