Microfluidic Chips for Life Sciences-A Comparison of Low Entry Manufacturing Technologies

Microfluidics for adaptation of microorganisms to stress: design and application

Microfluidic systems have fundamentally transformed the realm of adaptive laboratory evolution (ALE) for microorganisms by offering unparalleled control over environmental conditions, thereby optimizing mutant generation and desired trait selection. This review summarizes the substantial influence of microfluidic technologies and their design paradigms on microbial adaptation, with a primary focus on leveraging spatial stressor concentration gradients to enhance microbial growth in challenging environments. Specifically, microfluidic platforms tailored for scaled-down ALE processes not only enable highly autonomous and precise setups but also incorporate novel functionalities. These capabilities encompass fostering the growth of biofilms alongside planktonic cells, refining selection gradient profiles, and simulating adaptation dynamics akin to natural habitats. The integration of these aspects enables shaping phenotypes under pressure, presenting an unprecedented avenue for developing robust, stress-resistant strains, a feat not easily attainable using conventional ALE setups. The versatility of these microfluidic systems is not limited to fundamental research but also offers promising applications in various areas of stress resistance. As microfluidic technologies continue to evolve and merge with cutting-edge methodologies, they possess the potential not only to redefine the landscape of microbial adaptation studies but also to expedite advancements in various biotechnological areas. KEY POINTS: • Microfluidics enable precise microbial adaptation in controlled gradients. • Microfluidic ALE offers insights into stress resistance and distinguishes between resistance and persistence. • Integration of adaptation-influencing factors in microfluidic setups facilitates efficient generation of stress-resistant strains.

Biocatalytic Foams from Microdroplet-Formulated Self-Assembling Enzymes

Industrial biocatalysis plays an important role in the development of a sustainable economy, as enzymes can be used to synthesize an enormous range of complex molecules under environmentally friendly conditions. To further develop the field, intensive research is being conducted on process technologies for continuous flow biocatalysis in order to immobilize large quantities of enzyme biocatalysts in microstructured flow reactors under conditions that are as gentle as possible in order to realize efficient material conversions. Here, monodisperse foams consisting almost entirely of enzymes covalently linked via SpyCatcher/SpyTag conjugation are reported. The biocatalytic foams are readily available from recombinant enzymes via microfluidic air-in-water droplet formation, can be directly integrated into microreactors, and can be used for biocatalytic conversions after drying. Reactors prepared by this method show surprisingly high stability and biocatalytic activity. The physicochemical characterization of the new materials is described and exemplary applications in biocatalysis are shown using two-enzyme cascades for the stereoselective synthesis of chiral alcohols and the rare sugar tagatose.

Charge controlled interactions between DNA-modified silica nanoparticles and fluorosurfactants in microfluidic water-in-oil droplets

Microfluidic droplets are an important tool for studying and mimicking biological systems, e.g., to examine with high throughput the interaction of biomolecular components and the functionality of natural cells, or to develop basic principles for the engineering of artificial cells. Of particular importance is the approach to generate a biomimetic membrane by supramolecular self-assembly of nanoparticle components dissolved in the aqueous phase of the droplets at the inner water/oil interface, which can serve both to mechanically reinforce the droplets and as an interaction surface for cells and other components. While this interfacial assembly driven by electrostatic interaction of surfactants is quite well developed for water/mineral oil (W/MO) systems, no approaches have yet been described to exploit this principle for water/fluorocarbon oil (W/FO) emulsion droplets. Since W/FO systems exhibit not only better compartmentalization but also gas solubility properties, which is particularly crucial for live cell encapsulation and cultivation, we report here the investigation of charged fluorosurfactants for the self-assembly of DNA-modified silica nanoparticles (SiNP-DNA) at the interface of microfluidic W/FO emulsions. To this end, an efficient multicomponent Ugi reaction was used to synthesize the novel fluorosurfactant M4SURF to study the segregation and accumulation of negatively charged SiNP-DNA at the inner interface of microfluidic droplets. Comparative measurements were performed with the negatively charged fluorosurfactant KRYTOX, which can also induce SiNP-DNA segregation in the presence of cations. The segregation dynamics is characterized and preliminary results of cell encapsulation in the SiNP-DNA functionalized droplets are shown.

Tuning the fabrication of knotted reactors via 3D printing techniques and materials

Although three-dimensional (3D) printing technologies can customize a diverse range of devices, cross-3D printing technique/material comparisons aimed at optimizing the fabrication of analytical devices have been rare. In this study, we evaluated the surface features of the channels in knotted reactors (KRs) fabricated using fused deposition modeling (FDM) 3D printing [with poly(lactic acid) (PLA), polyamide, and acrylonitrile butadiene styrene filaments], and digital light processing and stereolithography 3D printing with photocurable resins. Also, their ability to retain Mn, Co, Ni, Cu, Zn, Cd, and Pb ions was evaluated to achieve the maximal sensitivities of these metal ions. After optimizing the techniques and materials for 3D printing of the KRs, the retention conditions, and the automatic analytical system, we observed good correlations (R > 0.9793) for the three 3D printing techniques in terms of the surface roughnesses of their channel sidewalls with respect to the signal intensities of their retained metal ions. The FDM 3D-printed PLA KR provided the best analytical performance, with the retention efficiencies of the tested metal ions all being greater than 73.9% and with the detection limits of the method ranging from 0.1 to 5.6 ng L^-1. We used this analytical method to perform analyses of the tested metal ions in several reference materials (CASS-4, SLEW-3, 1643f, and 2670a). Spike analyses of complicated real samples verified the reliability and applicability of this analytical method, highlighting the possibility of tuning 3D printing techniques and materials to optimize the fabrication of mission-oriented analytical devices.

Combining 3D Printing and Microfluidic Techniques: A Powerful Synergy for Nanomedicine

Nanomedicine has grown tremendously in recent years as a responsive strategy to find novel therapies for treating challenging pathological conditions. As a result, there is an urgent need to develop novel formulations capable of providing adequate therapeutic treatment while overcoming the limitations of traditional protocols. Lately, microfluidic technology (MF) and additive manufacturing (AM) have both acquired popularity, bringing numerous benefits to a wide range of life science applications. There have been numerous benefits and drawbacks of MF and AM as distinct techniques, with case studies showing how the careful optimization of operational parameters enables them to overcome existing limitations. Therefore, the focus of this review was to highlight the potential of the synergy between MF and AM, emphasizing the significant benefits that this collaboration could entail. The combination of the techniques ensures the full customization of MF-based systems while remaining cost-effective and less time-consuming compared to classical approaches. Furthermore, MF and AM enable highly sustainable procedures suitable for industrial scale-out, leading to one of the most promising innovations of the near future.

Macroporous Silicone Chips for Decoding Microbial Dark Matter in Environmental Microbiomes

Natural evolution has produced an almost infinite variety of microorganisms that can colonize almost any conceivable habitat. Since the vast majority of these microbial consortia are still unknown, there is a great need to elucidate this "microbial dark matter" (MDM) to enable exploitation in biotechnology. We report the fabrication and application of a novel device that integrates a matrix of macroporous elastomeric silicone foam (MESIF) into an easily fabricated and scalable chip design that can be used for decoding MDM in environmental microbiomes. Technical validation, performed with the model organism Escherichia coli expressing a fluorescent protein, showed that this low-cost, bioinert, and widely modifiable chip is rapidly colonized by microorganisms. The biological potential of the chip was then illustrated through targeted sampling and enrichment of microbiomes in a variety of habitats ranging from wet, turbulent moving bed biofilters and wastewater treatment plants to dry air-based environments. Sequencing analyses consistently showed that MESIF chips are not only suitable for sampling with high robustness but also that the material can be used to detect a broad cross section of microorganisms present in the habitat in a short time span of a few days. For example, results from the biofilter habitat showed efficient enrichment of microorganisms belonging to the enigmatic Candidate Phyla Radiation, which comprise ∼70% of the MDM. From dry air, the MESIF chip was able to enrich a variety of members of Actinobacteriota, which is known to produce specific secondary metabolites. Targeted sampling from a wastewater treatment plant where the herbicide glyphosate was added to the chip's reservoir resulted in enrichment of Cyanobacteria and Desulfobacteria, previously associated with glyphosate degradation. These initial case studies suggest that this chip is very well suited for the systematic study of MDM and opens opportunities for the cultivation of previously unculturable microorganisms.

Two-Phase Biocatalysis in Microfluidic Droplets

This Perspective discusses the literature related to two-phase biocatalysis in microfluidic droplets. Enzymes used as catalysts in biocatalysis are generally less stable in organic media than in their native aqueous environments; however, chemical and pharmaceutical compounds are often insoluble in water. The use of aqueous/organic two-phase media provides a solution to this problem and has therefore become standard practice for multiple biotransformations. In batch, two-phase biocatalysis is limited by mass transport, a limitation that can be overcome with the use of microfluidic systems. Although, two-phase biocatalysis in laminar flow systems has been extensively studied, microfluidic droplets have been primarily used for enzyme screening. In this Perspective, we summarize the limited published work on two-phase biocatalysis in microfluidic droplets and discuss the limitations, challenges, and future perspectives of this technology.

A Low-Cost 3-in-1 3D Printer as a Tool for the Fabrication of Flow-Through Channels of Microfluidic Systems

Recently published studies have shown that microfluidic devices fabricated by in-house three-dimensional (3D) printing, computer numerical control (CNC) milling and laser engraving have a good quality of performance. The 3-in-1 3D printers, desktop machines that integrate the three primary functions in a single user-friendly set-up are now available for computer-controlled adaptable surface processing, for less than USD 1000. Here, we demonstrate that 3-in-1 3D printer-based micromachining is an effective strategy for creating microfluidic devices and an easier and more economical alternative to, for instance, conventional photolithography. Our aim was to produce plastic microfluidic chips with engraved microchannel structures or micro-structured plastic molds for casting polydimethylsiloxane (PDMS) chips with microchannel imprints. The reproducability and accuracy of fabrication of microfluidic chips with straight, crossed line and Y-shaped microchannel designs were assessed and their microfluidic performance checked by liquid stream tests. All three fabrication methods of the 3-in-1 3D printer produced functional microchannel devices with adequate solution flow. Accordingly, 3-in-1 3D printers are recommended as cheap, accessible and user-friendly tools that can be operated with minimal training and little starting knowledge to successfully fabricate basic microfluidic devices that are suitable for educational work or rapid prototyping.

Portable Pathogen Diagnostics Using Microfluidic Cartridges Made from Continuous Liquid Interface Production Additive Manufacturing

Biomedical diagnostics based on microfluidic devices have the potential to significantly benefit human health; however, the manufacturing of microfluidic devices is a key limitation to their widespread adoption. Outbreaks of infectious disease continue to demonstrate the need for simple, sensitive, and translatable tests for point-of-care use. Additive manufacturing (AM) is an attractive alternative to conventional approaches for microfluidic device manufacturing based on injection molding; however, there is a need for development and validation of new AM process capabilities and materials that are compatible with microfluidic diagnostics. In this paper, we demonstrate the development and characterization of AM cartridges using continuous liquid interface production (CLIP) and investigate process characteristics and capabilities of the AM microfluidic device manufacturing. We find that CLIP accurately produces microfluidic channels as small as 400 μm and that it is possible to routinely produce fluid channels as small as 100 μm with high repeatability. We also developed a loop-mediated isothermal amplification (LAMP) assay for detection of E. coli from whole blood directly on the CLIP-based AM microfluidic cartridges, with a 50 cfu/μL limit of detection, validating the use of CLIP processes and materials for pathogen detection. The portable diagnostic platform presented in this paper could be used to investigate and validate other AM processes for microfluidic diagnostics and could be an important component of scaling up the diagnostics for current and future infectious diseases and pandemics.

3D-Printed Microfluidic Nanoelectrospray Ionization Source Based on Hydrodynamic Focusing

Nanoelectrospray ionization (nESI) mass spectrometry (MS) is an ideal detection method for microfluidic chips, and its performances depend on nESI emitters. However, the fabrication of monolithic nESI emitters in chips was difficult. Herein, we propose a three-dimensional (3D) printing method to develop a microfluidic nanoelectrospray ionization source (NIS), composed of a nESI emitter and other components. Firstly, the NIS was compatible with a 50 - 500 nL min^-1 nanoflows by imposing 3D hydrodynamic focusing to compensate for the total flow rate, achieving a 7.2% best relative standard deviation in the total ion current (TIC) profiles. Additionally, it was applied to probe thirteen organic chemicals, insulin, and lysozyme with adequate signal-to-noise ratios and an accuracy of m/z between 9.02 × 10^-1 and 1.48 × 10³ ppm. Finally, the NIS achieved comparable limits of detection compared with its commercial counterpart. Considering the standardized preparation of NIS, it would be a potential option to develop 3D-printed customized Chip-MS platforms.

Microfluidic Evolution-On-A-Chip Reveals New Mutations that Cause Antibiotic Resistance

Microfluidic devices can mimic naturally occurring microenvironments and create microbial population heterogeneities ranging from planktonic cells to biofilm states. The exposure of such populations to spatially organized stress gradients can promote their adaptation into complex phenotypes, which are otherwise difficult to achieve with conventional experimental setups. Here a microfluidic chip that employs precise chemical gradients in consecutive microcompartments to perform microbial adaptive laboratory evolution (ALE), a key tool to study evolution in fundamental and applied contexts is described. In the chip developed here, microbial cells can be exposed to a defined profile of stressors such as antibiotics. By modulating this profile, stress adaptation in the chip through resistance or persistence can be specifically controlled. Importantly, chip-based ALE leads to the discovery of previously unknown mutations in Escherichia coli that confer resistance to nalidixic acid. The microfluidic device presented here can enhance the occurrence of mutations employing defined micro-environmental conditions to generate data to better understand the parameters that influence the mechanisms of antibiotic resistance.

Segregation of Dispersed Silica Nanoparticles in Microfluidic Water-in-Oil Droplets: A Kinetic Study

Dispersed negatively charged silica nanoparticles segregate inside microfluidic water-in-oil (W/O) droplets that are coated with a positively charged lipid shell. We report a methodology for the quantitative analysis of this self-assembly process. By using real-time fluorescence microscopy and automated analysis of the recorded images, kinetic data are obtained that characterize the electrostatically-driven self-assembly. We demonstrate that the segregation rates can be controlled by the installment of functional moieties on the nanoparticle's surface, such as nucleic acid and protein molecules. We anticipate that our method enables the quantitative and systematic investigation of the segregation of (bio)functionalized nanoparticles in microfluidic droplets. This could lead to complex supramolecular architectures on the inner surface of micrometer-sized hollow spheres, which might be used, for example, as cell containers for applications in the life sciences.

Influence of the Degree of Cure in the Bulk Properties of Graphite Nanoplatelets Nanocomposites Printed via Stereolithography

In this work, we report on the fabrication via stereolithography (SLA) of acrylic-based nanocomposites using graphite nanoplatelets (GNPs) as an additive. GNPs are able to absorb UV-Vis radiation, thus blocking partial or totally the light path of the SLA laser. Based on this, we identified a range of GNP concentrations below 2.5 wt %, where nanocomposites can be successfully printed. We show that, even though GNP is well-dispersed along the polymeric matrix, nanocomposites presented lower degrees of cure and therefore worse mechanical properties when compared with pristine resin. However, a post-processing at 60 °C with UV light for 1 h eliminates this difference in the degree of cure, reaching values above 90% in all cases. In these conditions, the tensile strength is enhanced for 0.5 wt % GNP nanocomposites, while the stiffness is increased for 0.5-1.0 wt % GNP nanocomposites. Finally, we also demonstrate that 2.5 wt % GNP nanocomposites possess characteristic properties of semiconductors, which allows them to be used as electrostatic dispersion materials.

Bottom-Up Assembly of DNA-Silica Nanocomposites into Micrometer-Sized Hollow Spheres

Although DNA nanotechnology has developed into a highly innovative and lively field of research at the interface between chemistry, materials science, and biotechnology, there is still a great need for methodological approaches for bridging the size regime of DNA nanostructures with that of micrometer- and millimeter-sized units for practical applications. We report on novel hierarchically structured composite materials from silica nanoparticles and DNA polymers that can be obtained by self-assembly through the clamped hybridization chain reaction. The nanocomposite materials can be assembled into thin layers within microfluidically generated water-in-oil droplets to produce mechanically stabilized hollow spheres with uniform size distributions at high throughput rates. The fact that cells can be encapsulated in these microcontainers suggests that our concept not only contributes to the further development of supramolecular bottom-up manufacturing, but can also be exploited for applications in the life sciences.