Rapid assembly of multilayer microfluidic structures via 3D-printed transfer molding and bonding.

Casey C Glick,Joseph C Lin,Liwei Lin,Mitchell T Srimongkol,Roseanne H Warren,Dennis R Tekell,Aaron J Schwartz,William S Zhuang,Panitan A Satamalee

doi:10.1038/micronano.2016.63

Casey C Glick, Joseph C Lin + Show 7 more

Open Access

https://doi.org/10.1038/micronano.2016.63

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Abstract

A critical feature of state-of-the-art microfluidic technologies is the ability to fabricate multilayer structures without relying on the expensive equipment and facilities required by soft lithography-defined processes. Here, three-dimensional (3D) printed polymer molds are used to construct multilayer poly(dimethylsiloxane) (PDMS) devices by employing unique molding, bonding, alignment, and rapid assembly processes. Specifically, a novel single-layer, two-sided molding method is developed to realize two channel levels, non-planar membranes/valves, vertical interconnects (vias) between channel levels, and integrated inlet/outlet ports for fast linkages to external fluidic systems. As a demonstration, a single-layer membrane microvalve is constructed and tested by applying various gate pressures under parametric variation of source pressure, illustrating a high degree of flow rate control. In addition, multilayer structures are fabricated through an intralayer bonding procedure that uses custom 3D-printed stamps to selectively apply uncured liquid PDMS adhesive only to bonding interfaces without clogging fluidic channels. Using integrated alignment marks to accurately position both stamps and individual layers, this technique is demonstrated by rapidly assembling a six-layer microfluidic device. By combining the versatility of 3D printing while retaining the favorable mechanical and biological properties of PDMS, this work can potentially open up a new class of manufacturing techniques for multilayer microfluidic systems.

Highlights

Microfluidic devices for manipulating fluids have rapidly advanced since the 1980s because of their unique ability to fabricate lowcost, high-throughput platforms, for chemical and biological research and lab-on-a-chip technologies[1,2]
The component mold is fabricated via the 3D printing process (Figure 1a), and PDMS is applied (Figure 1c), cured, and released from the mold (Figure 1c) by means of the PDMS molding steps described in Section ‘MATERIALS AND METHODS’
Novel techniques were developed to fabricate double-sided or multilayer microfluidic devices that maintain the basic procedure of generating a Computer aided design (CAD) model, 3D-printed mold, and PDMS replica of the mold

Summary

Introduction

Microfluidic devices for manipulating fluids have rapidly advanced since the 1980s because of their unique ability to fabricate lowcost, high-throughput platforms, for chemical and biological research and lab-on-a-chip technologies[1,2]. Poly (dimethylsiloxane) (PDMS) is commonly used because of its numerous favorable properties, including its ease in manufacturing, reasonable cost, strength, transparency, and especially biocompatibility[4]

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Conclusion