Elucidating the mechanism of overcuring in microchannels fabricated via vat photopolymerization (VPP) for precise microfluidic chip printing

Abstract

Vat Photopolymerization (VPP) technology is highly regarded for precision micromachining applications like microfluidic chip fabrication, owing to its fine resolution, adaptability, and rapid prototyping capabilities. However, the challenge of resin over-curing resulting from UV energy penetration poses a significant obstacle in microchannel printing. This study addresses this challenge by investigating the intricate relationship between resin properties and over-curing. Diverse microfluidic chips were printed utilizing VPP technology, and the overall cross-sectional over-curing characteristics of the channels were systematically examined. A novel combination of the classical UV light curing model and computational Fluid-Structure Interaction (FSI) model with the VPP printing process was proposed to examine the complex hydrodynamics and exfoliation dynamics within VPP-printed microchannels. The simulation results suggest that resins with higher viscosities and surface roughness are better suited for microchannel printing. Subsequent experiments using five different resins verified these findings and showed that the microchannels obtained with resins of lower viscosity and surface roughness resins have an irregular trapezoidal cross-section, which is uncontrollable and unpredictable and seriously affects the microchannel printing accuracy. Conversely, resins with higher viscosity and surface roughness have an ideal rectangular cross-section, which can be compensated by the model further refined printing to print microchannel. Finally, microfluidic chips were printed using "high precision 8 K resin" and "8 K-clay resin" with higher viscosity and surface roughness. The results proved that the microchannels printed by these resins had the desired rectangular cross-section, which was consistent with the "DLP light-curing" model. This study elucidates, for the first time, the intricate interplay between resin properties, printing structure, and microchannel over-curing, and this provides a solid groundwork for advancing high-precision microfluidic chip fabrication via DLP printing.