Processes for the 3D Printing of Hydrodynamic Flow-Focusing Devices

Flow focusing is an important hydrodynamic technique for cytometric analysis, enabling the rapid study of cellular samples to identify a variety of biological processes. To date, the majority of flow-focusing devices are fabricated using conventional photolithography or flame processing of glass capillaries. This article presents a suite of low-cost, millifluidic, flow-focusing devices that were fabricated using a desktop sterolithgraphy (SLA) 3D printer. The suite of SLA printing strategies consists of a monolithic SLA method and a hybrid molding process. In the monolithic SLA approach, 1.3 mm square millifluidic channels were printed as a single piece. The printed device does not require any post processing, such as bonding or surface polishing for optical access. The hybrid molding approach consists of printing a mold using the SLA 3D printer. The mold is treated to an extended UV exposure and oven baked before using PDMS as the molding material for the channel. To demonstrate the viability of these channels, we performed a series of experiments using several flow-rate ratios to show the range of focusing widths that can be achieved in these devices. The experiments are validated using a numerical model developed in ANSYS.

Batch Fabrication of a Polydimethylsiloxane Based Stretchable Capacitive Strain Gauge Sensor for Orthopedics

Polymer-based capacitive strain gauges are a novel and promising concept for measuring large displacements and strains in various applications. These novel sensors allow for high strain, well above the maximum values achieved with state-of-the-art strain gauges (Typ. 1%). In recent years, a lot of interest in this technology has existed in orthopedics, where the sensors have been used to measure knee laxity caused by a tear of the anterior cruciate ligament (ACL), and for other ligament injuries. The validation of this technology in the field has a very low level of maturity, as no fast, reproducible, and reliable manufacturing process which allows mass production of sensors with low cost exists. For this reason, in this paper, a new approach for the fabrication of polymer-based capacitive strain gauges is proposed, using polydimethylsiloxane (PDMS) as base material. It allows (1) the fast manufacturing of sensor batches with reproducible geometry, (2) includes a fabrication step for embedding rigid electrical contacts on the sensors, and (3) is designed to produce sensor batches in which the size, the number, and the position of the sensors can be adapted to the patient’s anatomy. In the paper, the process repeatability and the robustness of the design are successfully proven. After 1000 large-strain elongation cycles, in the form of accelerated testing caused much higher strains than in the above-mentioned clinical scenario, the sensor’s electrical contacts remained in place and the functionalities were unaltered. Moreover, the prototype of a patient customizable patch, embedding multiple sensors, was produced.

The revolution of PDMS microfluidics in cellular biology

Microfluidics is revolutionizing the way research on cellular biology has been traditionally conducted. The ability to control the cell physicochemical environment by adjusting flow conditions, while performing cellular analysis at single-cell resolution and high-throughput, has made microfluidics the ideal choice to replace traditional in vitro models. However, such a revolution only truly started with the advent of polydimethylsiloxane (PDMS) as a microfluidic structural material and soft-lithography as a rapid manufacturing technology. Indeed, before the "PDMS age," microfluidic technologies were: costly, time-consuming and, more importantly, accessible only to specialized laboratories and users. The simplicity of molding PDMS in various shapes along with its inherent properties (transparency, biocompatibility, and gas permeability) has spread the applications of innovative microfluidic devices to diverse and important biological fields and clinical studies. This review highlights how PDMS-based microfluidic systems are innovating pre-clinical biological research on cells and organs. These devices were able to cultivate different cell lines, enhance the sensitivity and diagnostic effectiveness of numerous cell-based assays by maintaining consistent chemical gradients, utilizing and detecting the smallest number of analytes while being high-throughput. This review will also assist in identifying the pitfalls in current PDMS-based microfluidic systems to facilitate breakthroughs and advancements in healthcare research.

Fluidic circuit board with modular sensor and valves enables stand-alone, tubeless microfluidic flow control in organs-on-chips

Organs-on-chips are a unique class of microfluidic in vitro cell culture models, in which the in vivo tissue microenvironment is mimicked. Unfortunately, their widespread use is hampered by their operation complexity and incompatibility with end-user research settings. To address these issues, many commercial and non-commercial platforms have been developed for semi-automated culture of organs-on-chips. However, these organ-on-chip culture platforms each represent a closed ecosystem, with very little opportunity to interchange and integrate components from different platforms or to develop new ones. The translational organ-on-chip platform (TOP) is a multi-institutional effort to develop an open platform for automated organ-on-chip culture and integration of components from various developers. Central to TOP is the fluidic circuit board (FCB), a microfluidic plate with the form factor of a typical well plate. The FCB enables microfluidic control of multiple components like sensors or organ-on-chip devices through an interface based on openly available standards. Here, we report an FCB to integrate commercial and in-house developed components forming a stand-alone flow control system for organs-on-chips. The control system is able to achieve constant and pulsatile flow recirculation through a connected organ-on-chip device. We demonstrate that this system is able to automatically perfuse a heart-on-chip device containing co-cultures of cardiac tissues derived from human pluripotent stem cell-derived cardiomyocytes and monolayers of endothelial cells for five days. Altogether, we conclude that open technology platforms allow the integration of components from different sources to form functional and fit-for-purpose organ-on-chip systems. We anticipate that open platforms will play a central role in catalyzing and maturing further technological development of organ-on-chip culture systems.

Ultrasensitive Label-Free Nucleic-Acid Biosensors Based on Bimodal Waveguide Interferometers

The bimodal waveguide (BiMW) biosensor is an innovative common path interferometric sensor based on the evanescent field detection principle. This biosensor allows for the direct detection of virtually any biomolecular interaction in a label-free scheme by using specific biorecognition elements. Due to its inherent ultrasensitivity, it has been employed for the monitoring of relevant nucleic-acid sequences such as mRNA transcripts or microRNAs present at the attomolar-femtomolar concentration level in human samples. The application of the BiMW biosensor to detect these nucleic acids can be a powerful analytical tool for diagnosis and prognosis of complex illnesses, such as cancer, where these biomarkers play a major role. The BiMW sensor is fabricated using standard silicon-based microelectronics technology, which allows its miniaturization and cost-effective production, meeting the requirements of portability and disposability for the development of point-of-care (PoC) sensing platforms.In this chapter, we describe the working principle of the BiMW biosensor as well as its application for the analysis of nucleic acids. Concretely, we show a detailed description of DNA functionalization procedures and the complete analysis of two different RNA biomarkers for cancer diagnosis: (1) the analysis of mRNA transcripts generated by alternative splicing of Fas gene, and (2) the detection of miRNA 181a from urine liquid biopsies, for the early diagnosis of bladder cancer. The biosensing detection is performed by a direct assay in real time, by monitoring the changes in the intensity pattern of the light propagating through the BiMW biosensor, due to the hybridization of the target with the specific DNA probe previously functionalized on the BiMW sensor surface.

Microfluidic models of the human circulatory system: versatile platforms for exploring mechanobiology and disease modeling

The human circulatory system is a marvelous fluidic system, which is very sensitive to biophysical and biochemical cues. The current animal and cell culture models do not recapitulate the functional properties of the human circulatory system, limiting our ability to fully understand the complex biological processes underlying the dysfunction of this multifaceted system. In this review, we discuss the unique ability of microfluidic systems to recapitulate the biophysical, biochemical, and functional properties of the human circulatory system. We also describe the remarkable capacity of microfluidic technologies for exploring the complex mechanobiology of the cardiovascular system, mechanistic studying of cardiovascular diseases, and screening cardiovascular drugs with the additional benefit of reducing the need for animal models. We also discuss opportunities for further advancement in this exciting field.

Continuous Monitoring Reveals Protective Effects of N-Acetylcysteine Amide on an Isogenic Microphysiological Model of the Neurovascular Unit

Microphysiological systems mimic the in vivo cellular ensemble and microenvironment with the goal of providing more human-like models for biopharmaceutical research. In this study, the first such model of the blood-brain barrier (BBB-on-chip) featuring both isogenic human induced pluripotent stem cell (hiPSC)-derived cells and continuous barrier integrity monitoring with <2 min temporal resolution is reported. Its capabilities are showcased in the first microphysiological study of nitrosative stress and antioxidant prophylaxis. Relying on off-stoichiometry thiol-ene-epoxy (OSTE+) for fabrication greatly facilitates assembly and sensor integration compared to the prevalent polydimethylsiloxane devices. The integrated cell-substrate endothelial resistance monitoring allows for capturing the formation and breakdown of the BBB model, which consists of cocultured hiPSC-derived endothelial-like and astrocyte-like cells. Clear cellular disruption is observed when exposing the BBB-on-chip to the nitrosative stressor linsidomine, and the barrier permeability and barrier-protective effects of the antioxidant N-acetylcysteine amide are reported. Using metabolomic network analysis reveals further drug-induced changes consistent with prior literature regarding, e.g., cysteine and glutathione involvement. A model like this opens new possibilities for drug screening studies and personalized medicine, relying solely on isogenic human-derived cells and providing high-resolution temporal readouts that can help in pharmacodynamic studies.

Experimental fluid dynamics characterization of a novel micropump-mixer

The application of lab-on-a-chip systems to biomedical engineering and medical biology is rapidly growing. Reciprocating micropumps show significant promise as automated bio-fluid handling systems and as active reagent-to-sample mixers. Here, we describe a thorough fluid dynamic analysis of an active micro-pump-mixer designed for applications of preclinical blood analysis and clinical diagnostics in hematology. Using high-speed flow visualization and micro-particle image velocimetry measurements, a parametric study is performed to investigate the fluid dynamics of six discrete modes of micropump operation. With this approach, we identify an actuation regime that results in optimal sample flow rates while concomitantly maximizing reagent-to-sample mixing.

Application of Microfluidic Chip Technology in Food Safety Sensing

Food safety analysis is an important procedure to control food contamination and supervision. It is urgently needed to construct effective methods for on-site, fast, accurate and popular food safety sensing. Among them, microfluidic chip technology exhibits distinguish advantages in detection, including less sample consumption, fast detection, simple operation, multi-functional integration, small size, multiplex detection and portability. In this review, we introduce the classification, material, processing and application of the microfluidic chip in food safety sensing, in order to provide a good guide for food safety monitoring.

Active Micropump-Mixer for Rapid Antiplatelet Drug Screening in Whole Blood

There is a need for scalable automated lab-on-chip systems incorporating precise hemodynamic control that can be applied to high-content screening of new more efficacious antiplatelet therapies. This paper reports on the development and characterization of a novel active micropump-mixer microfluidic to address this need. Using a novel reciprocating elastomeric micropump design, we take advantage of the flexible structural and actuation properties of this framework to manage the hemodynamics for on-chip platelet thrombosis assay on type 1 fibrillar collagen, using whole blood. By characterizing and harnessing the complex three-dimensional hemodynamics of the micropump operation in conjunction with a microvalve controlled reagent injection system we demonstrate that this prototype can act as a real-time assay of antiplatelet drug pharmacokinetics. In a proof-of-concept preclinical application, we utilize this system to investigate the way in which rapid dosing of human whole blood with isoform selective inhibitors of phosphatidylinositol 3-kinase dose dependently modulate platelet thrombus dynamics. This modular system exhibits utility as an automated multiplexable assay system with applications to high-content chemical library screening of new antiplatelet therapies.

Micropatterning of planar metal electrodes by vacuum filling microfluidic channel geometries

We present a simple, facile method to micropattern planar metal electrodes defined by the geometry of a microfluidic channel network template. By introducing aqueous solutions of metal into reversibly adhered PDMS devices by desiccation instead of flow, we are able to produce difficult to pattern "dead end" or discontinuous features with ease. We characterize electrodes fabricated using this method and perform electrical lysis of mammalian cancer cells and demonstrate their use as part of an antibody capture assay for GFP. Cell lysis in microwell arrays is achieved using the electrodes and the protein released is detected using an antibody microarray. We show how the template channels used as part of the workflow for patterning the electrodes may be produced using photolithography-free methods, such as laser micromachining and PDMS master moulding, and demonstrate how the use of an immiscible phase may be employed to create electrode spacings on the order of 25-50 μm, that overcome the current resolution limits of such methods. This work demonstrates how the rapid prototyping of electrodes for use in total analysis systems can be achieved on the bench with little or no need for centralized facilities.

Elastomeric microvalve geometry affects haemocompatibility

This paper reports on the parameters that determine the haemocompatibility of elastomeric microvalves for blood handling in microfluidic systems. Using a comprehensive investigation of blood function, we describe a hierarchy of haemocompatibility as a function of microvalve geometry and identify a "normally-closed" v-gate pneumatic microvalve design that minimally affects blood plasma fibrinogen and von Willebrand factor composition, minimises effects on erythrocyte structure and function, and limits effects on platelet activation and aggregation, while facilitating rapid switching control for blood sample delivery. We propose that the haemodynamic profile of valve gate geometries is a significant determinant of platelet-dependent biofouling and haemocompatibility. Overall our findings suggest that modification of microvalve gate geometry and consequently haemodynamic profile can improve haemocompatibility, while minimising the requirement for chemical or protein modification of microfluidic surfaces. This biological insight and approach may be harnessed to inform future haemocompatible microfluidic valve and component design, and is an advance towards lab-on-chip automation for blood based diagnostic systems.

Label-Free Optofluidic Nanobiosensor Enables Real-Time Analysis of Single-Cell Cytokine Secretion

Single-cell analysis of cytokine secretion is essential to understand the heterogeneity of cellular functionalities and develop novel therapies for multiple diseases. Unraveling the dynamic secretion process at single-cell resolution reveals the real-time functional status of individual cells. Fluorescent and colorimetric-based methodologies require tedious molecular labeling that brings inevitable interferences with cell integrity and compromises the temporal resolution. An innovative label-free optofluidic nanoplasmonic biosensor is introduced for single-cell analysis in real time. The nanobiosensor incorporates a novel design of a multifunctional microfluidic system with small volume microchamber and regulation channels for reliable monitoring of cytokine secretion from individual cells for hours. Different interleukin-2 secretion profiles are detected and distinguished from single lymphoma cells. The sensor configuration combined with optical spectroscopic imaging further allows us to determine the spatial single-cell secretion fingerprints in real time. This new biosensor system is anticipated to be a powerful tool to characterize single-cell signaling for basic and clinical research.

Fabrication of truly 3D microfluidic channel using 3D-printed soluble mold

The field of complex microfluidic channels is rapidly expanding toward channels with variable cross-sections (i.e., beyond simple rounded channels with a constant diameter), as well as channels whose trajectory can be outside of a single plane. This paper introduces the use of three-dimensional (3D) printed soluble wax as cast molds for rapid fabrication of truly arbitrary microfluidic polydimethylsiloxane (PDMS) channels that are not achieved through typical soft lithography. The molds are printed directly from computer-aided design files, followed by simple dissolution using a solvent after molding PDMS, making rapid prototyping of microfluidic devices possible in hours. As part of the fabrication method, the solubility of several build materials in solvents and their effect on PDMS were investigated to remove the 3D-printed molds from inside the replicated PDMS microfluidic channels without damage. Technology limits, including surface roughness and resolution by comparing the designed channels with fabricated cylindrical channels with various diameters, are also characterized. We reproduced a 3D image of an actual human cerebral artery as cerebral artery-shaped PDMS channels with a diameter of 240 μm to prove the developed fabrication technique. It was confirmed that the fabricated vascular channels were free from any leakage by observing the fluorescence fluid fill.

An automated optofluidic biosensor platform combining interferometric sensors and injection moulded microfluidics

A primary limitation preventing practical implementation of photonic biosensors within point-of-care platforms is their integration with fluidic automation subsystems. For most diagnostic applications, photonic biosensors require complex fluid handling protocols; this is especially prominent in the case of competitive immunoassays, commonly used for detection of low-concentration, low-molecular weight biomarkers. For this reason, complex automated microfluidic systems are needed to realise the full point-of-care potential of photonic biosensors. To fulfil this requirement, we propose an on-chip valve-based microfluidic automation module, capable of automating such complex fluid handling. This module is realised through application of a PDMS injection moulding fabrication technique, recently described in our previous work, which enables practical fabrication of normally closed pneumatically actuated elastomeric valves. In this work, these valves are configured to achieve multiplexed reagent addressing for an on-chip diaphragm pump, providing the sample and reagent processing capabilities required for automation of cyclic competitive immunoassays. Application of this technique simplifies fabrication and introduces the potential for mass production, bringing point-of-care integration of complex automated microfluidics into the realm of practicality. This module is integrated with a highly sensitive, label-free bimodal waveguide photonic biosensor, and is demonstrated in the context of a proof-of-concept biosensing assay, detecting the low-molecular weight antibiotic tetracycline.

Porous PDMS structures for the storage and release of aqueous solutions into fluidic environments

Typical microfluidic systems take advantage of multiple storage reservoirs, pumps and valves for the storage, driving and release of buffers and other reagents. However, the fabrication, integration, and operation of such components can be difficult. In particular, the reliance of such components on external off-chip equipment limits their utility for creating self-sufficient, stand-alone microfluidic systems. Here, we demonstrate a porous sponge made of polydimethylsiloxane (PDMS), which is fabricated by templating microscale water droplets using a T-junction microfluidic structure. High-resolution microscopy reveals that this sponge contains a network of pores, interconnected by small holes. This unique structure enables the sponge to passively release stored solutions very slowly. Proof-of-concept experiments demonstrate that the sponge can be used for the passive release of stored solutions into narrow channels and circular well plates, with the latter used for inducing intracellular calcium signalling of immobilised endothelial cells. The release rate of stored solutions can be controlled by varying the size of interconnecting holes, which can be easily achieved by changing the flow rate of the water injected into the T-junction. We also demonstrate the active release of stored liquids into a fluidic channel upon the manual compression of the sponge. The developed PDMS sponge can be easily integrated into complex micro/macro fluidic systems and prepared with a wide array of reagents, representing a new building block for self-sufficient microfluidic systems.

Fabrication of PDMS microfluidic devices with 3D wax jetting

Network flowing on the 3D PDMS microfluidic chips fabricated with replication of a 3D printed wax mold.