Fabrication of Irregularity-Free, Highly Circular Cross-Sectional Microchannel

Abstract

Microchannels typically have rectangular cross-sections, whereas biological channels, such as blood vessels and airways, have circular cross-sections. The difference in cross-sections causes different fluidic behaviors, resulting in differences between fluidic behavior in microchannels and biological channels. To simulate fluidic behavior in vitro, circular cross-sectional microchannels are required. We developed a circular cross-sectional microchannel with a smooth channel wall, free from cracks and irregularities. In the fabrication process of the circular cross-sectional microchannel, uncured polydimethylsiloxane (PDMS) was inserted into a rectangular cross-sectional microchannel. Then, the PDMS was pushed out by the introduction of compressed air before the curing process. During the introduction of compressed air, we observed the behavior of the uncured PDMS and found the formation and movement of protrusions along the microchannel. After pushing out the uncured PDMS, the residual PDMS was cured, resulting in a circular cross-sectional microchannel. The fabrication method was examined by varying the channel orientation and airflow direction. In the case of the horizontal orientation and airflow in an opposite direction, the circularity of the microchannel was greater than 0.99 at the centimeter scale in all cross-sections along the microchannel.