This paper discusses the development and application of an adaptive slicing algorithm for
use with Digital Light Processing (DLP) for the manufacture of micro chemical reactors. Micro
reactors have highly complex constructions and DLP has a proven ability to deliver features at
the micro level with high accuracy. However, DLP fails to provide a truly smooth profiled
surface finish which could influence fluid flow through entrance and exit apertures and along
snaking micro channels. Ensuring smooth surfaces will minimise energy losses in the fluid flow
path. Generally, layer based manufacturing techniques incur a trade off between build time and
resolution. The algorithms used in this study attempt to mitigate this to some degree by
calculating locations where high resolution is required through surface profiling techniques and
adjusts the layer thickness accordingly. It is proposed that this adaptive layering technique may
improve surface roughness and reduce friction related energy losses along micro channels within
chemical reactor applications.Mechanical Engineerin