Optimizing Rapid Prototype Development Through Femtosecond Laser Ablation and Finite Element Method Simulation for Enhanced Separation in Microfluidics

Abstract

In recent years, microfluidic systems have emerged as promising tools for blood separation and analysis. However, conventional methods for prototyping microfluidic systems can be slow and expensive. In this study, we present a novel approach to rapid prototyping that combines femtosecond laser ablation and finite element method (FEM) simulation. The optimization of the prototyping process was achieved through systematic characterization of the laser ablation process and the application of FEM simulation to predict the flow behavior of the microfluidic devices. Using a dean-coupled inertial flow device (DCIFD) that comprises one channel bend and three outlets side-channels. DCIF is a phenomenon that occurs in curved microfluidic channels and is considered by the existence of inconsequential flow patterns perpendicular to the main flow direction. The DCIF can enhance the separation efficiency in microfluidic devices by inducing lateral migration of particles or cells towards specific locations along the channel. This lateral migration can be controlled by adjusting the curvature and dimensions of the channel, as well as the flow rate and properties of the fluid. Overall, DCIF can provide a valuable means of achieving efficient and high-throughput separation of particles or cells in microfluidic devices. Therefore, various microfluidics designs that contain different outlet channels were studied in this research to improve blood plasma separation efficiency. Results from imitated blood flow experiments showed positive results for fluid flow and particle separation. The study also found that incorporating three various channel widths is the key to achieving efficient plasma separation, indicating that this result could serve as a guideline for future microfluidics geometry specifications in the field of blood plasma separation. According to the FEM simulation, the highest separation percentage for both microparticle sizes was obtained by incorporating a variable outlet channel width into the same microfluidic device. The FEM simulation revealed that around 95% of the larger microparticles separated while 98% of the smaller microparticles separated. This is consistent with the imitated blood separation results, which showed that 91% of the larger microparticles separated and around 93% of the smaller microparticles were separated. Overall, our results demonstrate that the combination of femtosecond laser ablation and FEM simulation significantly improved the prototyping speed and efficiency while maintaining high blood separation performance.