CO2 laser machining for microfluidics mold fabrication from PMMA with applications on viscoelastic focusing, electrospun nanofiber production, and droplet generation

Low Cost, Ease-of-Access Fabrication of Microfluidic Devices Using Wet Paper Molds

Rapid prototyping methods enable the widespread adoption of microfluidic technologies by empowering end-users from non-engineering disciplines to make devices using processes that are rapid, simple and inexpensive. In this work, we developed a liquid molding technique to create silicone/PDMS microfluidic devices by replica molding. To construct a liquid mold, we use inexpensive adhesive-backed paper, an acetate backing sheet, and an off-the-shelf digital cutter to create paper molds, which we then wet with predetermined amounts of water. Due to the immiscibility of water and PDMS, mold patterns can be effectively transferred onto PDMS similarly to solid molds. We demonstrate the feasibility of these wet paper molds for the fabrication of PDMS microfluidic devices and assess the influence of various process parameters on device yield and quality. This method possesses some distinct benefits compared to conventional techniques such as photolithography and 3D printing. First, we demonstrate that the shape of a channel's cross-section may be altered from rectangular to semicircular by merely modifying the wetting parameters. Second, we illustrate how electrical impedance can be utilized as a marker for inspecting mold quality and identifying defects in a non-invasive manner without using visual tools such as microscopes or cameras. As a proof-of-concept device, we created a microfluidic T-junction droplet generator to produce water droplets in mineral oil ranging in size from 1.2 µL to 75 µL. We feel that this technology is an excellent addition to the microfluidic rapid prototyping toolbox and will find several applications in biological research.

Curved Film Microstructure Arrays Fabricated via Mechanical Stretching

We report on curved film microstructure arrays fabricated through polydimethylsiloxane (PDMS) film buckling induced by mechanical stretching. In the process of the microstructure preparation, a PDMA film is glued on a bidirectionally prestretched PDMS sheet that has a square distributed hole array on its surface. After releasing the prestrain, the film microstructure array is created spontaneously. The fabricated microstructures possess a spherical surface and demonstrate very good uniformity. The film microstructure arrays can serve as microlens arrays with a focal length of 1010 μm. The microstructure formation mechanism is investigated via theoretical analysis and numerical simulation. The simulation results agree well with the experimental results. The prestrain applied by mechanical stretching during the fabrication has an important effect on the shape of the resulting film microstructures. The microstructure geometry can be easily tuned through controlling the applied prestrain.