Multiscale 2PP and LCD 3D Printing for High-Resolution Membrane-Integrated Microfluidic Chips

This paper presents strategies that attempt to solve two key problems facing the commercialization of microfluidics: cost reduction in microfluidic chip manufacturing and microfluidic device driver development. To reduce the cost of microfluidic chip manufacturing, we propose to use of three-dimensional (3D) printers for direct digital manufacturing (DDM). An evaluation of 3D micro-scale structure printing using several 3D printers is reported, and some of the technical issues to be addressed in the future are suggested. To evaluate micro-scale printing, three types of 3D printers, with the ability to print structures on the scale of several hundred meters, were selected by first screening six 3D printers. Line and space patterns with line widths of 100–500 µm and an aspect ratio of one were printed and evaluated. The estimated critical dimension was around 200 µm. The manufacturing of a monolithic microfluidic chip with embedded channels was also demonstrated. Monolithic microfluidic chips with embedded microchannels having 500 × 500 and 250 × 250 µm2 cross sections and 2–20 mm lengths were printed, and the fidelity of the channel shape, residual supporting material, and flow of liquid water were evaluated. The liquid flow evaluation showed that liquid water could flow through all of the microchannels with the 500 × 500 µm2 cross section, whereas this was not possible through some of the channels with the 250 × 250 µm2 cross section because of the residual resin or supporting material. To reduce the device-driver cost, we propose to use of the centrifugal microfluidic concept. An autonomous microfluidic device that could implement sequential flow control under a steadily rotating condition was printed. Four-step flow injection under a steadily rotating condition at 1500 rpm was successfully demonstrated without any external triggering such as changing the rotational speed.

This paper presents a micro fluidic fusion chip for generating Ca-alginate microcapsules with different concentrations. Using MEMS technology, we designed and fabricated a PDMS microfluidic chip, which contained a micron rating 3D electrode as a replacement for the planar electrode made of indium tin oxide, a pillar-induced fusion zone, and an s-shaped observation zone. We used this microfluidic chip to generate Ca-alginate microcapsules uniformly sized but covered in different bovine serum albumin (BSA) concentrations, and found that the sizes ranged between $\mathbf{181 \mu \mathrm{m}}$ and $\mathbf{161 \mu \mathrm{m}}$ . After putting the three differently-sized microcapsules and three different BSA concentrations into Phosphate Buffered Saline for drug release, we observed through the UV IVisible Absorption Spectrometer that the Ca-alginate generated by microfluidic chip could release different drug concentrations at the same time. Thus, the proposed microfluidic chip can be applied to producing microcapsules of different sizes and with different drug concentrations.

Chapter 14 - Integration of three-dimensional printing and microfluidics

Microfluidic technology is an emerging interdisciplinary field that use micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, microelectronics, new materials and biomedical engineering. As one of the rapid prototyping methods, three-dimensional (3D) printing technique with rapid and cost-effective and integrated molding characteristics has became one of the important manufacturing technologies of microfluidic chip. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presented a comprehensive process research on the fabrication of fused deposition modeling (FDM) 3D printing PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D printing integrated microfluidic reactors in the reaction between copper ions and ammonia water. In the work, the thermal stress finite element model shown the printing platform temperature was a significant printing parameters to prevent warping and delamination in the 3D printing process. And a single printing molding technique was employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experiment method of 3D printing PMMA microchannels was carried out, and the optimized printing parameters resulted in a reduction of the microchannel profile to Ra 1.077μm. Finally, a set of chemical reaction experiments of copper ions and ammonia water were performed in a 3D printed microreactor. And color datum graph of copper hydroxide were obtained. This works provided a cheap and high-quality research method for the future research in water quality detection and chemical engineering.

Microfluidic technology is an emerging interdisciplinary field that uses micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, and biomedical engineering. As one of the rapid prototyping methods, the three-dimensional (3D) printing technique, which is rapid and cost-effective and has integrated molding characteristics, has become an important manufacturing technology for microfluidic chips. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presents a comprehensive process study on the fabrication of fused deposition modeling (FDM) 3D-printed PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D-printed integrated microfluidic reactors in the reaction between copper ions and ammonium hydroxide. In this work, a thermal stress finite element model shows that the printing platform temperature was a significant printing parameter to prevent warping and delamination in the 3D printing process. A single printing molding technique is employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experimental method of 3D-printed PMMA microchannels was carried out, and the optimized printing parameter resulted in a reduction in the microchannel profile to Ra 1.077 μm. Finally, a set of chemical reaction experiments of copper ions and ammonium hydroxide are performed in a 3D-printed microreactor. Furthermore, a color data graph of copper hydroxide is obtained. This study provides a cheap and high-quality research method for future research in water quality detection and chemical engineering.

This paper gives details on the use of 3D smart printing technology to fabricate microfluidic chips for integration into biosensors for the detection and diagnosis of diseases. Additive manufacturing, also known as 3D printing, is a process used to create complex, three-dimensional objects by adding layer upon layer of material until the desired shape is formed. Microfluidic chips are used to manipulate fluids through separation and mixing. Conventional microfluidic chip fabrication methods are expensive, require much experience to operate, and are time consuming, while 3D printing offers a solution to these challenges. The 3D printing technique prints models designed using a computer-aided design software such as Autodesk Fusion 360. In this work the authors show example microfluidic chips which were printed using a 3D printer, these include an X-channel chip, Y-channel chip and a lateral flow chip which can all be integrated with biosensing setups.

Fluidic chip fabrication technologies using three-dimensional (3D) printing have received broad attention recently. Herein, we describe a new method for fabricating polydimethylsiloxane (PDMS) fluidic chips using a 3D-printed polyvinyl alcohol (PVA) or acrylonitrile butadiene styrene (ABS) template and polymer coating. In this method, polyethylene glycol (PEG) was coated on the 3D-printed template. This coated template was immersed in liquid PDMS, and subsequently the PDMS was cured. Space can be created between the template and PDMS by removing this liquid PEG from the channel. This space renders template removal easier. A flow path is formed by dissolving the template with a solvent. These PDMS chips are used for flow injection measurement.

Re-usable multi-inlet PDMS fluidic connector

Microfluidic chips have shown their potential for applications in fields such as chemistry and biology, and 3D printing is increasingly utilized as the fabrication method for microfluidic chips. To address key issues such as the long printing time for conventional 3D printing of a single chip and the demand for rapid response in individualized microfluidic chip customization, we have optimized the use of DLP (digital light processing) technology, which offers faster printing speeds due to its surface exposure method. In this study, we specifically focused on developing a fast-manufacturing process for directly printing microfluidic chips, addressing the high cost of traditional microfabrication processes and the lengthy production times associated with other 3D printing methods for microfluidic chips. Based on the designed three-dimensional chip model, we utilized a DLP-based printer to directly print two-dimensional and three-dimensional microfluidic chips with photosensitive resin. To overcome the challenge of clogging in printing microchannels, we proposed a printing method that combined an open-channel design with transparent adhesive tape sealing. This method enables the rapid printing of microfluidic chips with complex and intricate microstructures. This research provides a crucial foundation for the development of microfluidic chips in biomedical research.

This paper presents an innovative approach for the prototyping of a microfluidic chip. By design modularization, unit mold batch fabrication, and mold assembly, the prototyping of polymeric microfluidic chips can be efficient and cost effective. The development of a microfluidic chip for protein reactions, including structure fabrication and chip testing for the initial and modified versions, is reported. Using the proposed approach, design modifications can be realized easily, without remaking photolithography masks or repeating the costly MEMS process. Initial results from testing two micro- fluidic chips (5cm by 1cm and 4cm by 3cm) prove the feasibility of the proposed method and show as well the potential for dramatic savings in time and cost in microfluidic chip prototyping.

3D printing technology has revolutionized medicine, particularly in orthopedic oncology and rehabilitation, by enabling the creation of customized implants, prostheses, and surgical tools. Its ability to produce complex, patient-specific structures with precise mechanical properties has significantly improved surgical outcomes and treatment effectiveness. Additionally, advancements in digital imaging and computer-aided design/computer-aided manufacturing (CAD/CAM) technologies have streamlined the design and manufacturing process, reducing production time while enhancing comfort and functionality. The continuous development of materials and printing techniques ensures further innovations in personalized medical solutions, making 3D printing a key tool in modern healthcare.The aim of this review is to evaluate the usefulness and development of 3D printing in rehabilitation, focusing on its impact on prosthetics and orthotics. The review of contemporary literature confirms that 3D printing significantly enhances the customization, efficiency, and accessibility of prosthetics and orthotics in rehabilitation. Studies indicate that 3D-printed devices provide comparable or superior biomechanical performance and comfort compared to traditionally manufactured solutions. Additionally, advancements in digital imaging and CAD/CAM technologies have optimized the design and production process, reducing manufacturing time while maintaining precision. 3D printing has emerged as a groundbreaking technology in rehabilitation, offering highly customizable and cost-effective solutions for prosthetics and orthotics. The integration of digital imaging and CAD/CAM technologies further refines the design process, ensuring greater precision. As research and material advancements continue, 3D printing is expected to play an increasingly significant role in rehabilitation, improving patient care and quality of life.

Статья рассматривает ключевую роль, которую 3D-печать играет в трансформации производственных моделей, а также её экономическое влияние на различные отрасли. В структуре IMRAD (Introduction, Methods, Results, and Discussion) рассмотрены основные аспекты. 3D-печать — это инновационная технология, произвольно преобразующая цифровые модели в физические объекты. В последние годы данная технология привлекла значительное внимание благодаря своей способности улучшать производственные процессы, снижать затраты и создавать новые возможности для различных секторов. В статье излагаются основные преимущества и потенциальные препятствия, связанные с интеграцией 3D-печати в производственные модели. Для исследования было применено несколько методологических подходов, включая качественный и количественный анализ. Основные источники данных включали текущие публикации, отчеты о рынке, а также интервью с экспертами в области аддитивного производства. Анализ данных проводился с использованием статистических методов и программного обеспечения для выявления ключевых тенденций и экономических эффектов. Результаты исследования продемонстрировали, что 3D-печать позволяет значительно сократить затраты на прототипирование, уменьшить время производства и повысить гибкость в создании сложных изделий. В примерах из автомобильной, медицинской и аэрокосмической отраслей показано, как использование 3D-печати способствует повышению эффективности и снижению затрат. Например, в медицинской отрасли 3D-печать используется для создания индивидуальных имплантатов, что значительно улучшает результаты лечения и снижает медицинские расходы. Обсуждение результатов подчеркивает необходимость дальнейших исследований по развитию материалов и технологий 3D-печати. Также отмечаются потенциал для снижения экологического воздействия за счет уменьшения отходов и оптимизации использования ресурсов. Однако, существует ряд вызовов, включая высокую стоимость оборудования и материалов, а также необходимость в специализированных знаниях и навыках. 3D-печать уже оказывает значительное влияние на различные отрасли, способствуя инновациям и экономической эффективности. В будущем, с улучшением технологий и снижением затрат, влияние 3D-печати будет продолжать расти, предлагая новые возможности для трансформации производственных моделей и повышения конкурентоспособности на глобальном рынке. The article examines the key role that 3D printing plays in transforming manufacturing models, as well as its economic impact on various industries. The main aspects are considered in the IMRAD structure (Introduction, Methods, Results, and Discussion). 3D printing is an innovative technology that arbitrarily transforms digital models into physical objects. In recent years, this technology has attracted significant attention due to its ability to improve manufacturing processes, reduce costs, and create new opportunities for various sectors. The article outlines the main advantages and potential obstacles associated with integrating 3D printing into manufacturing models. Several methodological approaches were applied for the study, including qualitative and quantitative analysis. The main data sources included current publications, market reports, and interviews with experts in the field of additive manufacturing. Data analysis was conducted using statistical methods and software to identify key trends and economic effects. The study results demonstrated that 3D printing allows for significant cost reduction in prototyping, reduced production time, and increased flexibility in creating complex products. Examples from the automotive, medical, and aerospace industries show how the use of 3D printing contributes to increased efficiency and cost reduction. For instance, in the medical field, 3D printing is used to create personalized implants, which significantly improves treatment outcomes and reduces medical expenses. The discussion of the results emphasizes the need for further research on the development of materials and 3D printing technologies. The potential for reducing environmental impact by minimizing waste and optimizing resource use is also noted. However, there are several challenges, including the high cost of equipment and materials, as well as the need for specialized knowledge and skills. 3D printing is already having a significant impact on various industries, promoting innovation and economic efficiency. In the future, with the improvement of technologies and cost reduction, the impact of 3D printing will continue to grow, offering new opportunities for transforming manufacturing models and increasing competitiveness in the global market.

This study demonstrated how to quickly and effectively print two-dimensional (2D) and three-dimensional (3D) microfluidic chips with a low-cost 3D sugar printer. The sugar printer was modified from a desktop 3D printer by redesigning the extruder, so the melting sugar could be extruded with pneumatic driving. Sacrificial sugar lines were first printed on a base layer followed by casting polydimethylsiloxane (PDMS) onto the layer and repeating. Microchannels were then printed in the PDMS solvent, microfluidic chips dropped into hot water to dissolve the sugar lines after the PDMS was solidified, and the microfluidic chips did not need further sealing. Different types of sugar utilized for printing material were studied with results indicating that maltitol exhibited a stable flow property compared with other sugars such as caramel or sucrose. Low cost is a significant advantage of this type of sugar printer as the machine may be purchased for only approximately $800. Additionally, as demonstrated in this study, the printed 3D microfluidic chip is a useful tool utilized for cell culture, thus proving the 3D printer is a powerful tool for medical/biological research.

Microfluidic devices are used in a myriad of biomedical applications such as cancer screening, drug testing, and point-of-care diagnostics. Three-dimensional (3D) printing offers a low-cost, rapid prototyping, efficient fabrication method, as compared to the costly—in terms of time, labor, and resources—traditional fabrication method of soft lithography of poly(dimethylsiloxane) (PDMS). Various 3D printing methods are applicable, including fused deposition modeling, stereolithography, and photopolymer inkjet printing. Additionally, several materials are available that have low-viscosity in their raw form and, after printing and curing, exhibit high material strength, optical transparency, and biocompatibility. These features make 3D-printed microfluidic chips ideal for biomedical applications. However, for developing devices capable of long-term use, fouling—by nonspecific protein absorption and bacterial adhesion due to the intrinsic hydrophobicity of most 3D-printed materials—presents a barrier to reusability. For this reason, there is a growing interest in anti-fouling methods and materials. Traditional and emerging approaches to anti-fouling are presented in regard to their applicability to microfluidic chips, with a particular interest in approaches compatible with 3D-printed chips.

In recent years, 3D printing, a highly promising additive manufacturing technique, has garnered significant attention as it allows the addition of fused materials layer by layer, to create intricate structures with ease and also offers the flexibility to incorporate multiple materials within the same structure simultaneously, reducing production time and costs. The versatility of 3D printing has led to its application in diverse fields, including nanotechnology. For nanotechnological applications, the manipulation of the 3D printing process to achieve specific patterns or designs is crucial for desired outcomes. As a result, continuous efforts are being made to advance the 3D printing process. Recent studies have focused on varying manufacturing process parameters to analyze their impact on the mechanical properties of 3D-printed products. Parameters such as raster width, raster angle, and printing speed have been identified as influencing factors, particularly on the strength of the printed items. An exciting development in the application of 3D printing in nanotechnology involves integrating the synthesis of metal-organic frameworks (MOFs) into the 3D-printed porous structure. This innovation has opened up new possibilities, especially in fields like water treatment. The synthesis of Cu-based MOFs on 3D-printed porous PLA structures has been explored in this study, with different raster angles and air gaps. Decreasing the air gap and low raster angle have been found to increase MOF growth, and vice versa. Dispersion of MOFs reaches the maximum with an increase in air gap before starting to decrease for any further addition of air gap. Optimizing manufacturing parameters can maximize MOF availability, leading to enhanced adsorption performance for water treatment.