The fabrication of integrated lab-on-a-chip devices conventionally relies on disjointed workflows, requiring mask-dependent photolithography for electrode patterning and separate soft lithography processes for fluidic channelling. This study characterizes an integrated manufacturing workflow utilizing a single commercial LCD-based masked stereolithography (SLA) platform (Phrozen Sonic Mighty 8 K) to perform three distinct physical processes: maskless UV lithography for sensor patterning, high-resolution mold fabrication, and functional substrate printing. We quantify the lithographic fidelity of the LCD interface (30 μm limit), the mechanical shear strength of the device bonding, and the intrinsic surface wettability of the acrylate-based resin, which enables a simplified fabrication protocol with reduced reliance on plasma surface treatment. To validate the workflow, an electrochemical aptasensor for cardiac troponin I (cTnI) was fabricated and compared against standard mask-patterned controls. Electrochemical impedance spectroscopy and differential pulse voltammetry results demonstrate that despite the pixelation inherent to the LCD matrix, the 3D-assisted electrodes maintain excellent linearity (R2 0.99) in Randles–Ševčík diffusion analysis and achieve sensitive cTnI detection (0.1–1000 pg/ml). Furthermore, material cost analysis highlights a significant improvement in resource efficiency compared to traditional protocols. These findings demonstrate that high-resolution consumer LCD-based masked SLA platforms can serve as robust, single-instrument manufacturing stations that bridge the gap between benchtop prototyping and industrial mass production.
Baiyokvichit et al. (Sun,) studied this question.