Prototyping Of Microfluidic Devices Research Articles

A Rapid Prototyping Technique for Microfluidics with High Robustness and Flexibility.

In microfluidic device prototyping, master fabrication by traditional photolithography is expensive and time-consuming, especially when the design requires being repeatedly modified to achieve a satisfactory performance. By introducing a high-performance/cost-ratio laser to the traditional soft lithography, this paper describes a flexible and rapid prototyping technique for microfluidics. An ultraviolet (UV) laser directly writes on the photoresist without a photomask, which is suitable for master fabrication. By eliminating the constraints of fixed patterns in the traditional photomask when the masters are made, this prototyping technique gives designers/researchers the convenience to revise or modify their designs iteratively. A device fabricated by this method is tested for particle separation and demonstrates good properties. This technique provides a flexible and rapid solution to fabricating microfluidic devices for non-professionals at relatively low cost.

Inexpensive, rapid prototyping of microfluidic devices using overhead transparencies and a laser print, cut and laminate fabrication method.

We describe a technique for fabricating microfluidic devices with complex multilayer architectures using a laser printer, a CO2 laser cutter, an office laminator and common overhead transparencies as a printable substrate via a laser print, cut and laminate (PCL) methodology. The printer toner serves three functions: (i) it defines the microfluidic architecture, which is printed on the overhead transparencies; (ii) it acts as the adhesive agent for the bonding of multiple transparency layers; and (iii) it provides, in its unmodified state, printable, hydrophobic 'valves' for fluidic flow control. By using common graphics software, e.g., CorelDRAW or AutoCAD, the protocol produces microfluidic devices with a design-to-device time of ∼40 min. Devices of any shape can be generated for an array of multistep assays, with colorimetric detection of molecular species ranging from small molecules to proteins. Channels with varying depths can be formed using multiple transparency layers in which a CO2 laser is used to remove the polyester from the channel sections of the internal layers. The simplicity of the protocol, availability of the equipment and substrate and cost-effective nature of the process make microfluidic devices available to those who might benefit most from expedited, microscale chemistry.

Experimental validation of a simple, low-cost, T-junction droplet generator fabricated through 3D printing

Three-dimensional printing has been recently proposed and assessed for continuous flow microfluidic devices. In this paper the focus is on a new application of this rapid and low cost method for microfluidic device prototyping: droplets production through a T-junction generator. The feasibility of this new methodology is assessed by means of an experimental study in which the statistical parameters which characterize the production of droplets are analyzed. Furthermore, this study assesses the validity of previous theoretical and experimental results, obtained for a PDMS T-junction droplet generator, also in the case of a 3D printed Acrylonitrile microfluidic chip. Finally, the feasibility of producing monodisperse droplets by analyzing the polydispersity index of the prepared droplets is demonstrated.

Highly hydrophilic microfluidic device prototyping using a novel poly(dimethylsiloxane)-based polymeric mix

We present a novel methodology to create in a simple and fast way an interpenetrating polymer network biomaterial, mixing 2-hydroxyethil methacrylate and poly(dimethylsiloxane), for long-lasting highlyhydrophilic microfluidic device prototyping.

Ultra-rapid prototyping of flexible, multi-layered microfluidic devices via razor writing

The fabrication of microfluidic devices is often still a time-consuming and costly process. Here we introduce a very simple and cheap microfabrication process based on "razor writing", also termed xurography, for the ultra-rapid prototyping of microfluidic devices. Thin poly(dimethylsiloxane) (PDMS) membranes are spin-coated on flexible plastic foil and cut into user-defined shapes with a bench-top cutter plotter. The PDMS membranes can then be assembled into desirable microdevices via plasma bonding. The plastic foil allows manipulation of exceptionally thin (30-300 μm) PDMS layers and can be readily peeled after fabrication. This versatile technique can be used to produce a wide variety of microfluidic device prototypes within just a few hours.

Rapid prototyping of microfluidic devices with integrated wrinkled gold micro-/nano textured electrodes for electrochemical analysis.

Fully-integrated electro-fluidic systems with micro-/nano-scale features have a wide range of applications in lab-on-a-chip systems used for biosensing, biological sample processing, and environmental monitoring. Rapid prototyping of application-specific electro-fluidic systems is envisioned to facilitate the testing, validation, and market translation of several lab-on-a-chip systems. Towards this goal, we developed a rapid prototyping process for creating wrinkled micro-/nano-textured electrodes on shrink memory polymers, fabricating microfluidics using molds patterned by a craft-cutter, and bonding electrical and fluidic circuitries using a PDMS partial curing method optimized for creating void-free bonds at the side walls and surfaces of tall (>5 μm) micro-/nano-textured wrinkled electrodes. The resulting electro-fluidic devices, featuring closely spaced high topography electrodes for electrochemical analysis, can withstand flow-rates and burst pressures larger than 25 mL min(-1) and 125 kPa, respectively. In addition, the fully-integrated electrochemical flow-cell developed here demonstrates excellent electrochemical behaviour, with negligible scan to scan variation for over 100 cyclic voltammetry scans, and expected redox signatures measured under various voltage scan rates and fluidic flow rates.

Advances in three-dimensional rapid prototyping of microfluidic devices for biological applications.

The capability of 3D printing technologies for direct production of complex 3D structures in a single step has recently attracted an ever increasing interest within the field of microfluidics. Recently, ultrafast lasers have also allowed developing new methods for production of internal microfluidic channels within the bulk of glass and polymer materials by direct internal 3D laser writing. This review critically summarizes the latest advances in the production of microfluidic 3D structures by using 3D printing technologies and direct internal 3D laser writing fabrication methods. Current applications of these rapid prototyped microfluidic platforms in biology will be also discussed. These include imaging of cells and living organisms, electrochemical detection of viruses and neurotransmitters, and studies in drug transport and induced-release of adenosine triphosphate from erythrocytes.

Adhesive Transfer Soft Lithography: Low-Cost and Flexible Rapid Prototyping of Microfluidic Devices

A simple and low-cost approach was proposed for prototyping PDMS based microfluidic devices by transferringadhesive film microstructures onto a flexible substrate as a mould for PDMS replicas. The microstructures were engravedon an adhesive coated film using a commercial cutting plotter and then transferred (or laminated) onto a flexiblesubstrate, allowing for engraved isolated patterns. The proposed technique was demonstrated by a hydrodynamic focusingmicrofluidic device, having splitting and re-combining sheath channels. The whole processing could be finished within 1h in a normal laboratory environment. This approach offers an easy, flexible and rapid prototyping of microfluidic andlab-on-a-chip devices to users without expertise in microfabrication. In addition, by minimizing the use of chemicals, theprocess becomes more environmentally friendly than conventional photolithography based micro-fabrication techniques.

Stainless Steel Pinholes for Fast Fabrication of High-Performance Microchip Electrophoresis Devices by CO2 Laser Ablation

With the introduction of hobby laser engravers/cutters, the use of CO2 laser micromachining on poly(methyl methacrylate) (PMMA) has the potential for flexible, low cost, rapid prototyping of microfluidic devices. Unfortunately, the feature size created by most entry-level CO2 laser micromachining systems is too large to become a functional tool in analytical microfluidics. In this paper, we report a novel method to reduce the feature size of microchannels and the bulges formed at the rim of the channel during CO2 laser micromachining by passing the laser beam through a stainless steel pinhole. Without the pinhole, the channel width was typically 300 μm wide. However, when 50 or 35 μm diameter pinholes were used, channel widths of 60 and 25 μm, respectively, could be obtained. The height of the bulge deposited directly next to the channel was reduced to less than 0.8 μm with the pinhole during ablation. Separations of fluorescent dyes on devices ablated with and without the pinhole were compared. On devices fabricated with the pinhole, the number of theoretical plates/m was 2.2-fold higher compared to devices fabricated without the pinhole, and efficiencies comparable to embossed PMMA and laser ablated glass chips were obtained. A mass-produced commercial hobby laser (retailing at ∼$2500), when equipped with a $500 pinhole, represents a rapid and low-cost approach to the rapid fabrication of rigid plastic microchips including the narrow microchannels required for microchip electrophoresis.

Photomasks Fabrication Based on Optical Reduction for Microfluidic Applications

A procedure for fabrication of photomasks on photographic films with minimum feature achievable of about 20 μm, which are particularly suitable for the fast prototyping of microfluidic devices, has been improved. We used a commercial photographic enlarger in reverse mode obtaining 10:1 reduction factor with error less than 1%. Masks have been characterized by optical transmission measurement and contact profilometry: the exposed region completely absorbs light in the wavelength region explored, while the non-exposed region is transparent from 350 nm on; the average film thickness is of 410 nm and its roughness is about 120 nm. A PDMS microfluidic device has been realized and tested in order to prove the effectiveness of designed photomasks used with the common UV light box.

Investigation of the maskless lithography technique for the rapid and cost-effective prototyping of microfluidic devices in laboratories

This paper describes maskless lithography as a rapid and cost-effective technique for fabricating high-quality microfluidic devices in laboratories. The detailed effects of exposure parameters on microstructure features are explored. A quantitative analysis of these effects provides insights into the device design and the selection of optimum processing parameters. To overcome the limitation of small exposure area, subregion stitching and sequential exposure are adopted for fabricating larger patterns. Seamless stitching between adjacent exposure subregions is achieved by optimizing the grayscale values of the stitching side/corner. These data are also valuable for exploring grayscale and multi-step lithography. Various hydrodynamic microdevices are then fabricated and characterized to validate the optimized parameters.

Photopolymerization of a perfluoropolyether oligomer and photolithographic processes for the fabrication of microfluidic devices

A perfluoropolyether based photocured polymer is proposed as structural material for the fabrication and easy prototyping of microfluidic devices. The kinetics of photopolymerization and the fluoropolymer characterization is reported, assessing the suitability of the material: it results transparent, thermally resistant, with a good dimensional stability and a chemical resistance much higher than polydimethylsiloxane, material currently used in microfluidics. The direct fabrication of microchannels is finally presented by direct photopolymerization under UV light irradiation through photomasks: the transfer of micropatterns was successful.

A new UV-curing elastomeric substrate for rapid prototyping of microfluidic devices

Rapid prototyping in the design cycle of new microfluidic devices is very important for shortening time-to-market. Researchers are facing the challenge to explore new and suitable substrates with simple and efficient microfabrication techniques. In this paper, we introduce and characterize a UV-curing elastomeric polyurethane methacrylate (PUMA) for rapid prototyping of microfluidic devices. The swelling and solubility of PUMA in different chemicals is determined. Time-dependent measurements of water contact angle show that the native PUMA is hydrophilic without surface treatment. The current monitoring method is used for measurement of the electroosmotic flow mobility in the microchannels made from PUMA. The optical, physical, thermal and mechanical properties of PUMA are evaluated. The UV-lithography and molding process is used for making micropillars and deep channel microfluidic structures integrated to the supporting base layer. Spin coating is characterized for producing different layer thicknesses of PUMA resin. A device is fabricated and tested for examining the strength of different bonding techniques such as conformal, corona treating and semi-curing of two PUMA layers in microfluidic application and the results show that the bonding strengths are comparable to that of PDMS. We also report fabrication and testing of a three-layer multi inlet/outlet microfluidic device including a very effective fluidic interconnect for application demonstration of PUMA as a promising new substrate. A simple micro-device is developed and employed for observing the pressure deflection of membrane made from PUMA as a very effective elastomeric valve in microfluidic devices.

A “dry and wet hybrid” lithography technique for multilevel replication templates: Applications to microfluidic neuron culture and two-phase global mixing

A broad range of microfluidic applications, ranging from cell culture to protein crystallization, requires multilevel devices with different heights and feature sizes (from micrometers to millimeters). While state-of-the-art direct-writing techniques have been developed for creating complex three-dimensional shapes, replication molding from a multilevel template is still the preferred method for fast prototyping of microfluidic devices in the laboratory. Here, we report on a "dry and wet hybrid" technique to fabricate multilevel replication molds by combining SU-8 lithography with a dry film resist (Ordyl). We show that the two lithography protocols are chemically compatible with each other. Finally, we demonstrate the hybrid technique in two different microfluidic applications: (1) a neuron culture device with compartmentalization of different elements of a neuron and (2) a two-phase (gas-liquid) global micromixer for fast mixing of a small amount of a viscous liquid into a larger volume of a less viscous liquid.

Beyond PDMS: off-stoichiometry thiol–ene (OSTE) based soft lithography for rapid prototyping of microfluidic devices

In this article we introduce a novel polymer platform based on off-stoichiometry thiol-enes (OSTEs), aiming to bridge the gap between research prototyping and commercial production of microfluidic devices. The polymers are based on the versatile UV-curable thiol-ene chemistry but takes advantage of off-stoichiometry ratios to enable important features for a prototyping system, such as one-step surface modifications, tuneable mechanical properties and leakage free sealing through direct UV-bonding. The platform exhibits many similarities with PDMS, such as rapid prototyping and uncomplicated processing but can at the same time mirror the mechanical and chemical properties of both PDMS as well as commercial grade thermoplastics. The OSTE-prepolymer can be cast using standard SU-8 on silicon masters and a table-top UV-lamp, the surface modifications are precisely grafted using a stencil mask and the bonding requires only a single UV-exposure. To illustrate the potential of the material we demonstrate key concepts important in microfluidic chip fabrication such as patterned surface modifications for hydrophobic stops, pneumatic valves using UV-lamination of stiff and rubbery materials as well as micromachining of chip-to-world connectors in the OSTE-materials.

Let there be chip—towards rapid prototyping of microfluidic devices: one-step manufacturing processes

Microfluidics is an evolving scientific field with immense commercial potential: analytical applications, such as biochemical assay development, biochemical analysis and biosensors as well as chemical synthesis applications essentially require microfluidics for sample handling, treatment or readout. A number of techniques are available to create microfluidic structures today. On industrial scale replication techniques such as injection molding are the gold standard whereas academic research mostly focuses on replication by casting of soft elastomers such as polydimethylsiloxane (PDMS). Both of these techniques require the creation of a replication master thus creating the microfluidic structure only in the second process step—they can therefore be termed two-(or multi-)step manufacturing techniques. However, very often the number of pieces to be created of one specific microfluidic design is low, sometimes even as low as one. This raises the question if two-step manufacturing is an appropriate choice, particularly if short concept-to-chip times are required. In this case one-step manufacturing techniques that allow the direct creation of microfluidic structures from digital three-dimensional models are preferable. For these processes the number of parts per design is low (sometimes as low as one), but quick adaptation is possible by simply changing digital data. Suitable techniques include, among others, maskless or mask based stereolithography, fused deposition molding and 3D printing. This work intends to discuss the potential and application examples of such processes with a detailed view on applicable materials. It will also point out the advantages and the disadvantages of the respective technique. Furthermore this paper also includes a discussion about non-conventional manufacturing equipment and community projects that can be used in the production of microfluidic devices.

Rapid prototyping of microfluidic devices for integrating with FT-IR spectroscopic imaging

A versatile approach for the rapid prototyping of microfluidic devices suitable for use with FT-IR spectroscopic imaging is introduced. Device manufacture is based on the direct printing of paraffin onto the surface of an infrared transparent substrate, followed by encapsulation. Key features of this approach are low running costs, rapid production times, simplicity of design modifications and suitability for integration with FT-IR spectroscopic measurements. In the current experiments, the minimum width of channel walls was found to be approximately 120 mum and approximately 200 when a 25 mum and 12 mum spacer is used, respectively. Water and poly(ethylene glycol) are used as model fluids in a laminar flow regime, and are imaged in both transmission and attenuated total reflection (ATR) modes. It is established that adoption of transmission mode measurements yields superior sensitivity whilst the ATR mode is more suitable for quantitative analysis using strong spectral absorption bands. Results indicate that devices manufactured using this approach are suitable for use with in situ FT-IR spectroscopic imaging.

Print-and-Peel Fabrication for Microfluidics: What’s in it for Biomedical Applications?

This article reviews the development and the advances of print-and-peel (PAP) microfabrication. PAP techniques provide means for facile and expedient prototyping of microfluidic devices. Therefore, PAP has the potential for broadening the microfluidics technology by bringing it to researchers who lack regular or any accesses to specialized fabrication facilities and equipment. Microfluidics have, indeed, proven to be an indispensable toolkit for biological and biomedical research and development. Through accessibility to such methodologies for relatively fast and easy prototyping, PAP has the potential to considerably accelerate the impacts of microfluidics on the biological sciences and engineering. In summary, PAP encompasses: (1) direct printing of the masters for casting polymer device components; and (2) adding three-dimensional elements onto the masters for single-molding-step formation of channels and cavities within the bulk of the polymer slabs. Comparative discussions of the different PAP techniques, along with the current challenges and approaches for addressing them, outline the perspectives for PAP and how it can be readily adopted by a broad range of scientists and engineers.

Evaluation of micromechanical manufacturing processes for microfluidic devices

In this paper, several micromechanical manufacturing technologies were studied in order to characterize their performance for prototyping miniaturized geometries known as microchannels, which are the main geometric features of microfluidic devices. The technologies used were microend milling, wire electrodischarge machining/sandblasting, and abrasive water jet. Their capabilities were compared with lithography capabilities, which is the conventional process for microchannel manufacturing. The evaluation consists in a comprehensive study of surface quality and topography, made with the help of advanced contact and noncontact profilometers over each prototype. Also economical considerations have been taken into account in order to choose the most appropriate manufacturing process for the prototyping of microfluidic devices. The results show that microend milling process can compete with lithography, in terms of achieving acceptable levels of product quality and economics.

FLASH: A rapid method for prototyping paper-based microfluidic devices

This article describes FLASH (Fast Lithographic Activation of Sheets), a rapid method for laboratory prototyping of microfluidic devices in paper. Paper-based microfluidic devices are emerging as a new technology for applications in diagnostics for the developing world, where low cost and simplicity are essential. FLASH is based on photolithography, but requires only a UV lamp and a hotplate; no clean-room or special facilities are required (FLASH patterning can even be performed in sunlight if a UV lamp and hotplate are unavailable). The method provides channels in paper with dimensions as small as 200 microm in width and 70 microm in height; the height is defined by the thickness of the paper. Photomasks for patterning paper-based microfluidic devices can be printed using an ink-jet printer or photocopier, or drawn by hand using a waterproof black pen. FLASH provides a straightforward method for prototyping paper-based microfluidic devices in regions where the technological support for conventional photolithography is not available.