Capillary-driven automatic packaging

Precision enhanced alignment bonding technique with sacrificial strategy

This work proposes an "N2-1" sacrificial strategy to help to improve the accuracy of the bonding technique from the existing level. The target micropattern is copied N2 times, and (N2-1) of them are sacrificed to obtain the most accurate alignment. Meanwhile, a method for manufacturing auxiliary solid alignment lines on transparent materials is proposed to visualize auxiliary marks and facilitate the alignment. Though the principle and procedure of alignment are straightforward, the alignment accuracy substantially improved compared to the original method. With this technique, we have successfully fabricated a high-precision 3D electroosmotic micropump just using a conventional desktop aligner. Because of the high precision during the alignment, the flow velocity is up to 435.62 μm/s at a driven voltage of 40 V, which far exceeds the previous similar reports. Thus, we believe that it has great potential for high precision microfluidic device fabrications.

A portable and affordable aligner for the assembly of microfluidic devices

The incorporation of sophisticated capabilities within microfluidic devices often requires the assembly of different layers in a correct arrangement. For example, when it is desired to include electrodes inside microfluidic channels or to create 3D microfluidic structures. However, the alignment between different substrates at the microscale requires expensive equipment not available for all research groups. In this work, we present an affordable, compact and portable aligner for assembling multilayered composite microfluidic chips. The instrument is composed of aluminum machined pieces combined with precision stages and includes a digital microscope with a LED illumination system for monitoring the alignment process. An interchangeable holder was created for substrate fixing, allowing the bonding of PDMS with other materials. Microscopic visualization is achieved through any device with internet access, avoiding the need of a computer attached to the aligner. To test the performance of the aligner, the center of an indium tin oxide microelectrode on a glass substrate was aligned with the center of a microchannel in a PDMS chip. The accuracy and precision of the instrument are suited for many microfluidic applications. The small and inexpensive design of the aligner makes it a cost-effective option for small groups working in microfluidics.

A hinge-based aligner for fast, large-scale assembly of microfluidic chips

Microfluidics has shown its vitality in scientific research. But the lack of fast and straightforward approaches for aligning chip and easy-to-control on-chip valve still prevent microfluidic chips from becoming powerful commercial products. This work presents an aligner based on hinge structures, which we call a "hinge aligner", for aligning microfluidic chips. Two flat chip holders are connected by a connecting rod so that the chip holders can rotate relative to each other along the connecting rod, in the way a hinge works. The two chip holders contain pre-designed recesses for placing two chips which can align chips with 20 μm resolution. Meanwhile, with this hinge aligner, we can easily implement a fully sealed on-chip valve, which can prevent aqueous liquids from leaking even at 80 °C for 30 min. The real immunoassay result shows aligned microfluidic chips can detect protein with improved reproducibility in both high and low concentration of biomarkers.

Capillary microfluidics in microchannels: from microfluidic networks to capillaric circuits

Microfluidics offer economy of reagents, rapid liquid delivery, and potential for automation of many reactions, but often require peripheral equipment for flow control. Capillary microfluidics can deliver liquids in a pre-programmed manner without peripheral equipment by exploiting surface tension effects encoded by the geometry and surface chemistry of a microchannel. Here, we review the history and progress of microchannel-based capillary microfluidics spanning over three decades. To both reflect recent experimental and conceptual progress, and distinguish from paper-based capillary microfluidics, we adopt the more recent terminology of capillaric circuits (CCs). We identify three distinct waves of development driven by microfabrication technologies starting with early implementations in industry using machining and lamination, followed by development in the context of micro total analysis systems (μTAS) and lab-on-a-chip devices using cleanroom microfabrication, and finally a third wave that arose with advances in rapid prototyping technologies. We discuss the basic physical laws governing capillary flow, deconstruct CCs into basic circuit elements including capillary pumps, stop valves, trigger valves, retention valves, and so on, and describe their operating principle and limitations. We discuss applications of CCs starting with the most common usage in automating liquid delivery steps for immunoassays, and highlight emerging applications such as DNA analysis. Finally, we highlight recent developments in rapid prototyping of CCs and the benefits offered including speed, low cost, and greater degrees of freedom in CC design. The combination of better analytical models and lower entry barriers (thanks to advances in rapid manufacturing) make CCs both a fertile research area and an increasingly capable technology for user-friendly and high-performance laboratory and diagnostic tests.

Control and automation of multilayered integrated microfluidic device fabrication

Integrated microfluidics is a sophisticated three-dimensional (multi layer) solution for high complexity serial or parallel processes. Fabrication of integrated microfluidic devices requires soft lithography and the stacking of thin-patterned PDMS layers. Precise layer alignment and bonding is crucial. There are no previously reported standards for alignment of the layers, which is mostly performed using uncontrolled processes with very low alignment success. As a result, integrated microfluidics is mostly used in academia rather than in the many potential industrial applications. We have designed and manufactured a semiautomatic Microfluidic Device Assembly System (μDAS) for full device production. μDAS comprises an electrooptic mechanical system consisting of four main parts: optical system, smart media holder (for PDMS), a micropositioning xyzθ system and a macropositioning XY mechanism. The use of the μDAS yielded valuable information regarding PDMS as the material for device fabrication, revealed previously unidentified errors, and enabled optimization of a robust fabrication process. In addition, we have demonstrated the utilization of the μDAS technology for fabrication of a complex 3 layered device with over 12 000 micromechanical valves and an array of 64 × 64 DNA spots on a glass substrate with high yield and high accuracy. We increased fabrication yield from 25% to about 85% with an average layer alignment error of just ∼4 μm. It also increased our protein expression yields from 80% to over 90%, allowing us to investigate more proteins per experiment. The μDAS has great potential to become a valuable tool for both advancing integrated microfluidics in academia and producing and applying microfluidic devices in the industry.

Print-to-print: printer-enabled out-of-cleanroom multiobject microprinting method

Micropatterning techniques have gained growing interests from a broad range of engineering and biology researches as it realizes the high-throughput and highly quantitative investigations on miniature biological objects (e.g., cells and bacteria) by spatially defined micropatterns. However, most of the existing techniques rely on expensive instruments or intensive cleanroom access which may not be easy to be utilized in a regular biological laboratory. Here, we present the detailed procedures of a simple versatile microprinting process, referred to as Print-to-Print (P2P), to form multiobject micropatterns for potential biological applications. Only a solid-phase printer and custom-made superhydrophobic (SH) films are utilized for the printing and no thermal or chemical treatment is involved during the entire printing process. Moreover, the noncontact nature of droplet transferring and printing steps can be highly advantageous for sensitive biological uses. By the P2P process, a minimal feature resolution of 229 ± 17 μm has been successfully achieved. What's more, this approach has been applied to form micropatterning on various commonly used substrates in biology as well as multiobject co-patterns. In addition, the SH substrates have also been demonstrated to be reusable.

Microfluidic impact printer with interchangeable cartridges for versatile non-contact multiplexed micropatterning

Biopatterning has been increasingly used for well-defined cellular microenvironment, patterned surface topology, and guided biological cues; however, it meets challenges on biocompatibility, thermal and chemical sensitivity, as well as limited availability of reagents. In this paper, we aim at combining the desired features from non-contact inkjet printing and dot-matrix impact printing to establish a versatile multiplexed micropatterning platform, referred to as Microfluidic Impact Printer (MI-Printer), for emerging biomedical applications. Using this platform, we can achieve the distinct features of no cross-contamination, sub-microliter ink loading with a minimal dead volume, high-throughput printing, biocompatible non-contact processing, sequential patterning with self-alignment, wide adaptability for complex media (e.g., cell suspension or colloidal solutions), interchangeable/disposable cartridge design, and simple assembly and configuration, all highly desirable towards laboratory-based research and development. Specifically, the printing resolution of the MI-printer platform has been experimentally characterized and theoretically analysed. Optimal printing resolution of 80 μm has been repeatedly obtained. Furthermore, two useful functions of the MI-printer, multiplexed printing and combinatorial printing, have been experimentally demonstrated with less than 10 μm misalignment. Moreover, molecular and biological patterning, utilizing the multiplexed and combinatorial printing, has been implemented to illustrate the utility of this versatile printing technique for emerging biomedical applications.

Print-to-print: a facile multi-object micro-patterning technique

In recent years, micropatterning techniques have gained increasing popularity from a broad range of engineering and biology communities for the promise to establish highly quantitative investigations on miniature biological objects (e.g., cells and bacteria) with spatially defined microenvironments. However, majority of the existing techniques rely on cleanroom-based microfabrication and cannot be easily extended to a regular biological laboratory. In this paper, we present a simple versatile printing-based method, referred to as Print-to-Print (P2P), to form multi-object micropatterns for potential biological applications, along with our recent efforts to deliver out-of-cleanroom microfabrication solutions to the general public (Zhao et al. 2009), (Xing et al. 2011), (Wang et al. 2009), (Pan and Wang 2011), (Zhao et al. 2011). The P2P method employs only a commercially available solid-phase printer and custom-made superhydrophobic films. The entire patterning process does not involve any thermal or chemical treatment. Moreover, the non-contact nature of droplet transferring and printing steps can be highly advantageous for sensitive biological uses. Using the P2P process, a minimal feature resolution of 229 ± 17 μm has been successfully demonstrated. In addition, this approach has been applied to form biological micropatterning on various substrates as well as multi-object co-patterns on the commonly used surfaces. Finally, the reusability of superhydrophobic substrates has also been illustrated.

Universal nanopatternable interfacial bonding

A nanopatternable polydimethylsiloxane (PDMS) oligomer layer is demonstrated as an interfacial adhesive for its intrinsic transferability and universal adhesiveness. Utilizing the well-established surface modification and bonding techniques of PDMS surfaces, irreversible bonding is formed (up to 400 kPa) between a wide range of substrate pairs, representing ones within and across different materials categories, including metals, ceramics, thermoset, and thermoplastic polymers.

Three-dimensional fit-to-flow microfluidic assembly

Three-dimensional microfluidics holds great promise for large-scale integration of versatile, digitalized, and multitasking fluidic manipulations for biological and clinical applications. Successful translation of microfluidic toolsets to these purposes faces persistent technical challenges, such as reliable system-level packaging, device assembly and alignment, and world-to-chip interface. In this paper, we extended our previously established fit-to-flow (F2F) world-to-chip interconnection scheme to a complete system-level assembly strategy that addresses the three-dimensional microfluidic integration on demand. The modular F2F assembly consists of an interfacial chip, pluggable alignment modules, and multiple monolithic layers of microfluidic channels, through which convoluted three-dimensional microfluidic networks can be easily assembled and readily sealed with the capability of reconfigurable fluid flow. The monolithic laser-micromachining process simplifies and standardizes the fabrication of single-layer pluggable polymeric modules, which can be mass-produced as the renowned Lego(®) building blocks. In addition, interlocking features are implemented between the plug-and-play microfluidic chips and the complementary alignment modules through the F2F assembly, resulting in facile and secure alignment with average misalignment of 45 μm. Importantly, the 3D multilayer microfluidic assembly has a comparable sealing performance as the conventional single-layer devices, providing an average leakage pressure of 38.47 kPa. The modular reconfigurability of the system-level reversible packaging concept has been demonstrated by re-routing microfluidic flows through interchangeable modular microchannel layers.