Advances in Microfluidic Systems and Numerical Modeling in Biomedical Applications: A Review

The evolution in the biomedical engineering field boosts innovative technologies, with microfluidic systems standing out as transformative tools in disease diagnosis, treatment, and monitoring. Numerical simulation has emerged as a tool of increasing importance for better understanding and predicting fluid-flow behavior in microscale devices. This review explores fabrication techniques and common materials of microfluidic devices, focusing on soft lithography and additive manufacturing. Microfluidic systems applications, including nucleic acid amplification and protein synthesis, as well as point-of-care diagnostics, DNA analysis, cell cultures, and organ-on-a-chip models (e.g., lung-, brain-, liver-, and tumor-on-a-chip), are discussed. Recent studies have applied computational tools such as ANSYS Fluent 2024 software to numerically simulate the flow behavior. Outside of the study cases, this work reports fundamental aspects of microfluidic simulations, including fluid flow, mass transport, mixing, and diffusion, and highlights the emergent field of organ-on-a-chip simulations. Additionally, it takes into account the application of geometries to improve the mixing of samples, as well as surface wettability modification. In conclusion, the present review summarizes the most relevant contributions of microfluidic systems and their numerical modeling to biomedical engineering.

Pysanky to Microfluidics: An Innovative Wax-Based Approach to Low Cost, Rapid Prototyping of Microfluidic Devices

A wax-based contact printing method to create microfluidic devices is demonstrated. This printing technology demonstrates a new pathway to rapid, cost-effective device prototyping, eliminating the use of expensive micromachining equipment and chemicals. Derived from the traditional Ukrainian Easter egg painting technique called "pysanky" a series of microfluidic devices were created. Pysanky is the use of a heated wax stylus, known as a "kistka", to create micro-sized, intricate designs on the surface of an egg. The proposed technique involves the modification of an x-y-z actuation translation system with a wax extruder tip in junction with Polydimethysiloxane (PDMS) device fabrication techniques. Initial system optimization was performed considering design parameters such as extruder tip size, contact angle, write speed, substrate temperature, and wax temperature. Channels created ranged from 160 to 900 μm wide and 10 to 150 μm high based upon system operating parameters set by the user. To prove the capabilities of this technology, a series of microfluidic mixers were created via the wax technique as well as through traditional photolithography: a spiral mixer, a rainbow mixer, and a linear serial dilutor. A thermo-fluidic computational fluid dynamic (CFD) model was generated as a means of enabling rational tuning, critical to the optimization of systems in both normal and extreme conditions. A comparison between the computational and experimental models yielded a wax height of 57.98 μm and 57.30 μm, respectively, and cross-sectional areas of 11,568 μm2 and 12,951 μm2, respectively, resulting in an error of 1.18% between the heights and 10.76% between the cross-sectional areas. The device's performance was then compared using both qualitative and quantitative measures, considering factors such as device performance, channel uniformity, repeatability, and resolution.

Microfluidics: a concise review of the history, principles, design, applications, and future outlook

Microfluidic technologies have garnered significant attention due to their ability to rapidly process samples and precisely manipulate fluids in assays, making them an attractive alternative to conventional experimental methods. With the potential for revolutionary capabilities in the future, this concise review provides readers with insights into the fascinating world of microfluidics. It begins by introducing the subject's historical background, allowing readers to familiarize themselves with the basics. The review then delves into the fundamental principles, discussing the underlying phenomena at play. Additionally, it highlights the different aspects of microfluidic device design, classification, and fabrication. Furthermore, the paper explores various applications, the global market, recent advancements, and challenges in the field. Finally, the review presents a positive outlook on trends and draws lessons to support the future flourishing of microfluidic technologies.

Bio-inspired microfluidics: A review

Biomicrofluidics, a subdomain of microfluidics, has been inspired by several ideas from nature. However, while the basic inspiration for the same may be drawn from the living world, the translation of all relevant essential functionalities to an artificially engineered framework does not remain trivial. Here, we review the recent progress in bio-inspired microfluidic systems via harnessing the integration of experimental and simulation tools delving into the interface of engineering and biology. Development of "on-chip" technologies as well as their multifarious applications is subsequently discussed, accompanying the relevant advancements in materials and fabrication technology. Pointers toward new directions in research, including an amalgamated fusion of data-driven modeling (such as artificial intelligence and machine learning) and physics-based paradigm, to come up with a human physiological replica on a synthetic bio-chip with due accounting of personalized features, are suggested. These are likely to facilitate physiologically replicating disease modeling on an artificially engineered biochip as well as advance drug development and screening in an expedited route with the minimization of animal and human trials.

A Non-Sacrificial 3D Printing Process for Fabricating Integrated Micro/Mesoscale Molds

Three-dimensional printing technology has been implemented in microfluidic mold fabrication due to its freedom of design, speed, and low-cost fabrication. To facilitate mold fabrication processes and avoid the complexities of the soft lithography technique, we offer a non-sacrificial approach to fabricate microscale features along with mesoscale features using Stereolithography (SLA) printers to assemble a modular microfluidic mold. This helps with addressing an existing limitation with fabricating complex and time-consuming micro/mesoscale devices. The process flow, optimization of print time and feature resolution, alignments of modular devices, and the advantages and limitations with the offered technique are discussed in this paper.

Silicon-Based 3D Microfluidics for Parallelization of Droplet Generation

Both the diversity and complexity of microfluidic systems have experienced a tremendous progress over the last decades, enabled by new materials, novel device concepts and innovative fabrication routes. In particular the subfield of high-throughput screening, used for biochemical, genetic and pharmacological samples, has extensively emerged from developments in droplet microfluidics. More recently, new 3D device architectures enabled either by stacking layers of PDMS or by direct 3D-printing have gained enormous attention for applications in chemical synthesis or biomedical assays. While the first microfluidic devices were based on silicon and glass structures, those materials have not yet been significantly expanded towards 3D despite their high chemical compatibility, mechanical strength or mass-production potential. In our work, we present a generic fabrication route based on the implementation of vertical vias and a redistribution layer to create glass-silicon-glass 3D microfluidic structures. It is used to build different droplet-generating devices with several flow-focusing junctions in parallel, all fed from a single source. We study the effect of having several of these junctions in parallel by varying the flow conditions of both the continuous and the dispersed phases. We demonstrate that the generic concept enables an upscaling in the production rate by increasing the number of droplet generators per device without sacrificing the monodispersity of the droplets.

Rapid prototyping of microfluidic chips enabling controlled biotechnology applications in microspace

Rapid prototyping of microfluidic chips is a key enabler for controlled biotechnology applications in microspaces, as it allows for the efficient design and production of microfluidic systems. With rapid prototyping, researchers and engineers can quickly create and test new microfluidic chip designs, which can then be optimized for specific applications in biotechnology. One of the key advantages of microfluidic chips for biotechnology is the ability to manipulate and control biological samples in a microspace, which enables precise and controlled experiments under well-defined conditions. This is particularly useful for applications such as cell culture, drug discovery, and diagnostic assays, where precise control over the biological environment is crucial for obtaining accurate results. Established methods, for example, soft lithography, 3D printing, injection molding, as well as other recently highlighted innovative approaches, will be compared and challenges as well as limitations will be discussed. It will be shown that rapid prototyping of microfluidic chips enables the use of advanced materials and technologies, such as smart materials and digital sensors, which can further enhance the capabilities of microfluidic systems for biotechnology applications. Overall, rapid prototyping of microfluidic chips is an important enabling technology for controlled biotechnology applications in microspaces, as well as for upscaling it into macroscopic bioreactors, and its continued development and improvement will play a critical role in advancing the field. The review will highlight recent trends in terms of materials and competing approaches and shed light on current challenges on the way toward integrated microtechnologies. Also, the possibility to easy and direct implementation of novel functions (membranes, functionalization of interfaces, etc.) is discussed.

Picoliter Droplet Generation and Dense Bead-in-Droplet Encapsulation via Microfluidic Devices Fabricated via 3D Printed Molds

Picoliter-scale droplets have many applications in chemistry and biology, such as biomolecule synthesis, drug discovery, nucleic acid quantification, and single cell analysis. However, due to the complicated processes used to fabricate microfluidic channels, most picoliter (pL) droplet generation methods are limited to research in laboratories with cleanroom facilities and complex instrumentation. The purpose of this work is to investigate a method that uses 3D printing to fabricate microfluidic devices that can generate droplets with sizes <100 pL and encapsulate single dense beads mechanistically. Our device generated monodisperse droplets as small as ~48 pL and we demonstrated the usefulness of this droplet generation technique in biomolecule analysis by detecting Lactobacillus acidophillus 16s rRNA via digital loop-mediated isothermal amplification (dLAMP). We also designed a mixer that can be integrated into a syringe to overcome dense bead sedimentation and found that the bead-in-droplet (BiD) emulsions created from our device had <2% of the droplets populated with more than 1 bead. This study will enable researchers to create devices that generate pL-scale droplets and encapsulate dense beads with inexpensive and simple instrumentation (3D printer and syringe pump). The rapid prototyping and integration ability of this module with other components or processes can accelerate the development of point-of-care microfluidic devices that use droplet-bead emulsions to analyze biological or chemical samples with high throughput and precision.

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.

Facile microfabrication of three dimensional-patterned micromixers using additive manufacturing technology

This study investigates the manufacturing method of oblique patterns in microchannels and the effect of these patterns on mixing performance in microchannels. To fabricate three-dimensional (3D) and oblique patterns in microchannels, 3D printing and replica methods were utilized to mold patterns and microchannels, respectively. The angle and size of the patterns were controlled by the printing angle and resolution, respectively. The mixing efficiency was experimentally characterized, and the mixing principle was analyzed using computational fluid dynamics simulation. The analysis showed that the mixing channel cast from the mold printed with a printing angle of 30° and resolution of 300 μm exhibited the best mixing efficiency with a segregation index of approximately 0.05 at a Reynolds number of 5.4. This was because, as the patterns inside the microchannel were more oblique, “split” and “recombine” behaviors between two fluids were enhanced owing to the geometrical effect. This study supports the use of the 3D printing method to create unique patterns inside microchannels and improve the mixing performance of two laminar flows for various applications such as point-of-care diagnostics, lab-on-a-chip, and chemical synthesis.

Reducing the channel diameter of polydimethylsiloxane fluidic chips made by a 3D-printed sacrificial template and their application for flow-injection analysis

Fluidic chips have attracted considerable interest in recent years for their potential applications in analytical devices. Previously, we developed a method to fabricate polydimethylsiloxane (PDMS) fluidic chips via templates made using a low-priced commercial Fused Deposition Modeling (FDM) type 3D printer and polymer coatings. However, in general, methods using a template cannot form a flow channel thinner than the template thickness and the width. In this study, the inner wall of a PDMS fluidic chip was coated with PDMS to create a chip with a channel inner diameter smaller than a template. Then, by measuring the flow signal of methyl orange with a single line, the basic properties of the non-coated and coated chip were investigated. As a result, almost the same flow profile was obtained in non-coated and coated chips at the same linear velocity and the same sample injection length. By coating and narrowing the channel width, it is possible to save the amount of sample and carrier solution. Measuring hydrazine in water using a coated chip was also tried. The calibration curve indicated good linearity in the range of 1–6 ppm. However, a concentration point of 7 ppm deviated. The reason for this deviation was presumably due to inadequate mixing of the sample and reagent. By decreasing the flow rate, the calibration curve indicated good linearity in the range of 1–7 ppm.

Graphical abstract

Additive Manufacturing of Micro-Electro-Mechanical Systems (MEMS)

Recently, additive manufacturing (AM) processes applied to the micrometer range are subjected to intense development motivated by the influence of the consolidated methods for the macroscale and by the attraction for digital design and freeform fabrication. The integration of AM with the other steps of conventional micro-electro-mechanical systems (MEMS) fabrication processes is still in progress and, furthermore, the development of dedicated design methods for this field is under development. The large variety of AM processes and materials is leading to an abundance of documentation about process attempts, setup details, and case studies. However, the fast and multi-technological development of AM methods for microstructures will require organized analysis of the specific and comparative advantages, constraints, and limitations of the processes. The goal of this paper is to provide an up-to-date overall view on the AM processes at the microscale and also to organize and disambiguate the related performances, capabilities, and resolutions.

Biomimetic Wax Interfaces Facilitating Rehealable Polymer Composites

Epicuticular wax, the first protective film for numerous ground plant species, is crucial for modulating the evolution in plants. Since the waxy film is inherently thermoresponsive, many efforts focus on engineering materials for water/oil proofing, delivery, and collection, as well as microactuators by mimicking such film nature. Nonetheless, relatively fewer works address the mechanism of how the underlying substrates direct the reconstruction of waxy films while their temperature approaches the melting point. Here, we presented a strategy in which distinct frameworks of molten wax films could be examined among various substrates. Both “waxphobic” and “waxphilic” traits were first unveiled and could be achieved by the hydrophilic (water contact angle (WCA) = 42~82°) and hydrophobic (WCA = 109°) substrates, respectively. A theoretical model, based on experimental results, fluidic dynamics, and balance of surface energy, was developed to elucidate the above findings. Moreover, we demonstrated the above biomimetic epicuticular surface (BeSurface) can be applied for rewritable paper, erasable coding, and rehealable electronics without manual repairing. Remarkably, the healing time can be reduced down to 30 s, and the cycled folding test can be continued up to 500 times. All the new findings present the potentials of the BeSurface to improve the study of rehealable materials.

Programmable DNA-Based Boolean Logic Microfluidic Processing Unit

As molecular computing materials, information-encoded deoxyribonucleic acid (DNA) strands provide a logical computing process by cascaded and parallel chain reactions. However, the reactions in DNA-based combinational logic computing are mostly achieved through a manual process by adding desired DNA molecules in a single microtube or a substrate. For DNA-based Boolean logic, using microfluidic chips can afford automated operation, programmable control, and seamless combinational logic operation, similar to electronic microprocessors. In this paper, we present a programmable DNA-based microfluidic processing unit (MPU) chip that can be controlled via a personal computer for performing DNA calculations. To fabricate this DNA-based MPU, polydimethylsiloxane was cast using double-sided molding techniques for alignment between the microfluidics and valve switch. For a uniform surface, molds fabricated using a three-dimensional printer were spin-coated by a polymer. For programming control, the valve switch arms were operated by servo motors. In the MPU controlled via a personal computer or smartphone application, the molecules with two input DNAs and a logic template DNA were reacted for the basic AND and OR operations. Furthermore, the DNA molecules reacted in a cascading manner for combinational AND and OR operations. Finally, we demonstrated a 2-to-1 multiplexer and the XOR operation with a three-step cascade reaction using the simple DNA-based MPU, which can perform Boolean logic operations (AND, OR, and NOT). Through logic combination, this DNA-based Boolean logic MPU, which can be operated using programming language, is expected to facilitate the development of complex functional circuits such as arithmetic logical units and neuromorphic circuits.

Biomimetic Soft Polymer Microstructures and Piezoresistive Graphene MEMS Sensors Using Sacrificial Metal 3D Printing

Recent advances in 3D printing technology have enabled unprecedented design freedom across an ever-expanding portfolio of materials. However, direct 3D printing of soft polymeric materials such as polydimethylsiloxane (PDMS) is challenging, especially for structural complexities such as high-aspect ratio (>20) structures, 3D microfluidic channels (∼150 μm diameter), and biomimetic microstructures. This work presents a novel processing method entailing 3D printing of a thin-walled sacrificial metallic mold, soft polymer casting, and acidic etching of the mold. The proposed workflow enables the facile fabrication of various complex, bioinspired PDMS structures (e.g., 3D double helical microfluidic channels embedded inside high-aspect ratio pillars) that are difficult or impossible to fabricate using currently available techniques. The microfluidic channels are further infused with conductive graphene nanoplatelet ink to realize two flexible piezoresistive microelectromechanical (MEMS) sensors (a bioinspired flow/tactile sensor and a dome-like force sensor) with embedded sensing elements. The MEMS force sensor is integrated into a Philips 9000 series electric shaver to demonstrate its application in "smart" consumer products in the future. Aided by current trends in industrialization and miniaturization in metal 3D printing, the proposed workflow shows promise as a low-temperature, scalable, and cleanroom-free technique of fabricating complex, soft polymeric, biomimetic structures, and embedded MEMS sensors.

Particle movement and fluid behavior visualization using an optically transparent 3D-printed micro-hydrocyclone

A hydrocyclone is a macroscale separation device employed in various industries, with many advantages, including high-throughput and low operational costs. Translating these advantages to microscale has been a challenge due to the microscale fabrication limitations that can be surmounted using 3D printing technology. Additionally, it is difficult to simulate the performance of real 3D-printed micro-hydrocyclones because of turbulent eddies and the deviations from the design due to printing resolution. To address these issues, we propose a new experimental method for the direct observation of particle motion in 3D printed micro-hydrocyclones. To do so, wax 3D printing and soft lithography were used in combination to construct a transparent micro-hydrocyclone in a single block of polydimethylsiloxane. A high-speed camera and fluorescent particles were employed to obtain clear in situ images and to confirm the presence of the vortex core. To showcase the use of this method, we demonstrate that a well-designed device can achieve a 95% separation efficiency for a sample containing a mixture of (desired) stem cells and (undesired) microcarriers. Overall, we hope that the proposed method for the direct visualization of particle trajectories in micro-hydrocyclones will serve as a tool, which can be leveraged to accelerate the development of micro-hydrocyclones for biomedical applications.

Toward Vasculature in Skeletal Muscle-on-a-Chip through Thermo-Responsive Sacrificial Templates

Developing new approaches for vascularizing synthetic tissue systems will have a tremendous impact in diverse areas. One area where this is particularly important is developing new skeletal muscle tissue systems, which could be utilized in physiological model studies and tissue regeneration. To develop vascularized approaches a microfluidic on-chip design for creating channels in polymer systems can be pursued. Current microfluidic tissue engineering methods include soft lithography, rapid prototyping, and cell printing; however, these have limitations such as having their scaffolding being inorganic, less desirable planar vasculature geometry, low fabrication efficiency, and limited resolution. Here we successfully developed a circular microfluidic channel embedded in a 3D extracellular matrix scaffolding with 3D myogenesis. We used a thermo-responsive polymer approach with micromilling-molding and designed a mixture of polyester wax and paraffin wax to fabricate the sacrificial template for microfluidic channel generation in the scaffolding. These findings will impact a number of fields including biomaterials, biomimetic structures, and personalized medicine in the future.

A practical guide to rapid-prototyping of PDMS-based microfluidic devices: A tutorial

Micro total analytical systems (μTAS) are attractive to multiple fields that include chemistry, medicine and engineering due to their portability, low power usage, potential for automation, and low sample and reagent consumption, which in turn results in low waste generation. The development of fully-functional μTAS is an iterative process, based on the design, fabrication and testing of multiple prototype microdevices. Typically, microfabrication protocols require a week or more of highly-skilled personnel time in high-maintenance cleanroom facilities, which makes this iterative process cost-prohibitive in many locations worldwide. Rapid-prototyping tools, in conjunction with the use of polydimethylsiloxane (PDMS), enable rapid development of microfluidic structures at lower costs, circumventing these issues in conventional microfabrication techniques. Multiple rapid-prototyping methods to fabricate PDMS-based microfluidic devices have been demonstrated in literature since the advent of soft-lithography in 1998; each method has its unique advantages and drawbacks. Here, we present a tutorial discussing current rapid-prototyping techniques to fabricate PDMS-based microdevices, including soft-lithography, print-and-peel and scaffolding techniques, among other methods, specifically comparing resolution of the features, fabrication processes and associated costs for each technique. We also present thoughts and insights towards each step of the iterative microfabrication process, from design to testing, to improve the development of fully-functional PDMS-based microfluidic devices at faster rates and lower costs.

Microfluidic-Based Approaches in Targeted Cell/Particle Separation Based on Physical Properties: Fundamentals and Applications

Cell separation is a key step in many biomedical research areas including biotechnology, cancer research, regenerative medicine, and drug discovery. While conventional cell sorting approaches have led to high-efficiency sorting by exploiting the cell's specific properties, microfluidics has shown great promise in cell separation by exploiting different physical principles and using different properties of the cells. In particular, label-free cell separation techniques are highly recommended to minimize cell damage and avoid costly and labor-intensive steps of labeling molecular signatures of cells. In general, microfluidic-based cell sorting approaches can separate cells using "intrinsic" (e.g., fluid dynamic forces) versus "extrinsic" external forces (e.g., magnetic, electric field, etc.) and by using different properties of cells including size, density, deformability, shape, as well as electrical, magnetic, and compressibility/acoustic properties to select target cells from a heterogeneous cell population. In this work, principles and applications of the most commonly used label-free microfluidic-based cell separation methods are described. In particular, applications of microfluidic methods for the separation of circulating tumor cells, blood cells, immune cells, stem cells, and other biological cells are summarized. Computational approaches complementing such microfluidic methods are also explained. Finally, challenges and perspectives to further develop microfluidic-based cell separation methods are discussed.

Distributed Manufacturing of Open Source Medical Hardware for Pandemics

Distributed digital manufacturing offers a solution to medical supply and technology shortages during pandemics. To prepare for the next pandemic, this study reviews the state-of-the-art of open hardware designs needed in a COVID-19-like pandemic. It evaluates the readiness of the top twenty technologies requested by the Government of India. The results show that the majority of the actual medical products have some open source development, however, only 15% of the supporting technologies required to produce them are freely available. The results show there is still considerable research needed to provide open source paths for the development of all the medical hardware needed during pandemics. Five core areas of future research are discussed, which include (i) technical development of a wide-range of open source solutions for all medical supplies and devices, (ii) policies that protect the productivity of laboratories, makerspaces, and fabrication facilities during a pandemic, as well as (iii) streamlining the regulatory process, (iv) developing Good-Samaritan laws to protect makers and designers of open medical hardware, as well as to compel those with knowledge that will save lives to share it, and (v) requiring all citizen-funded research to be released with free and open source licenses.

Fabrication of unconventional inertial microfluidic channels using wax 3D printing

Inertial microfluidics has emerged over the past decade as a powerful tool to accurately control cells and microparticles for diverse biological and medical applications. Many approaches have been proposed to date in order to increase the efficiency and accuracy of inertial microfluidic systems. However, the effects of channel cross-section and solution properties (Newtonian or non-Newtonian) have not been fully explored, primarily due to limitations in current microfabrication methods. In this study, we overcome many of these limitations using wax 3D printing technology and soft lithography through a novel workflow, which eliminates the need for the use of silicon lithography and polydimethylsiloxane (PDMS) bonding. We have shown that by adding dummy structures to reinforce the main channels, optimizing the gap between the dummy and main structures, and dissolving the support wax on a PDMS slab to minimize the additional handling steps, one can make various non-conventional microchannels. These substantially improve upon previous wax printed microfluidic devices where the working area falls into the realm of macrofluidics rather than microfluidics. Results revealed a surface roughness of 1.75 μm for the printed channels, which does not affect the performance of inertial microfluidic devices used in this study. Channels with complex cross-sections were fabricated and then analyzed to investigate the effects of viscoelasticity and superposition on the lateral migration of the particles. Finally, as a proof of concept, microcarriers were separated from human mesenchymal stem cells using an optimized channel with maximum cell-holding capacity, demonstrating the suitability of these microchannels in the bioprocessing industry.

3D-printed PEEK reactors and development of a complete continuous flow system for chemical synthesis

This paper presents the development of milli- and microfluidic reactors made of polyether ether ketone (PEEK) and 3D-printed equipment for a complete continuous flow system.

Replication of a Printed Volatile Mold: a novel microfabrication method for advanced microfluidic systems

A novel and simple method to fabricate microchannels is reported based on an inkjet printing of a volatile solid mold. A liquid ink -1,6 hexanediol- ejected from a piezoelectric nozzle is instantaneously frozen when touching a cooled substrate. The created mold is then poured with PDMS. Once the PDMS is crosslinked, the ink is sublimated and the device is ready. With this approach it is possible to make microchannels on different nature surfaces such as glass, paper, uncross-linked PDMS layer or non planar substrates. The versatility of this method is illustrated by printing channels directly on commercial electrodes and measuring the channel capacitance. Moreover, millimetric height microfluidic systems are easily produced (aspect ratio [Formula: see text] 25) as well as 3D structures such as bridges. To demonstrate, we have fabricated a combinatorial microfluidic system which makes 6 mixtures from 4 initial solutions without any stacking and tedious alignment procedure.

Blood Cells Separation and Sorting Techniques of Passive Microfluidic Devices: From Fabrication to Applications

Since the first microfluidic device was developed more than three decades ago, microfluidics is seen as a technology that exhibits unique features to provide a significant change in the way that modern biology is performed. Blood and blood cells are recognized as important biomarkers of many diseases. Taken advantage of microfluidics assets, changes on blood cell physicochemical properties can be used for fast and accurate clinical diagnosis. In this review, an overview of the microfabrication techniques is given, especially for biomedical applications, as well as a synopsis of some design considerations regarding microfluidic devices. The blood cells separation and sorting techniques were also reviewed, highlighting the main achievements and breakthroughs in the last decades.

Fabrication of a Polydimethylsiloxane Fluidic Chip Using a Sacrificial Template Made by Fused Deposition Modeling 3D Printing and Application for Flow-injection Analysis

Fluidic chip fabrication technologies using three-dimensional (3D) printing have received broad attention recently. Herein, we describe a new method for fabricating polydimethylsiloxane (PDMS) fluidic chips using a 3D-printed polyvinyl alcohol (PVA) or acrylonitrile butadiene styrene (ABS) template and polymer coating. In this method, polyethylene glycol (PEG) was coated on the 3D-printed template. This coated template was immersed in liquid PDMS, and subsequently the PDMS was cured. Space can be created between the template and PDMS by removing this liquid PEG from the channel. This space renders template removal easier. A flow path is formed by dissolving the template with a solvent. These PDMS chips are used for flow injection measurement.

Replica moulded poly(dimethylsiloxane) microwell arrays induce localized endothelial cell immobilization for coculture with pancreatic islets

PolyJet three-dimensional (3D) printing allows for the rapid manufacturing of 3D moulds for the fabrication of cross-linked poly(dimethylsiloxane) microwell arrays (PMAs). As this 3D printing technique has a resolution on the micrometer scale, the moulds exhibit a distinct surface roughness. In this study, the authors demonstrate by optical profilometry that the topography of the 3D printed moulds can be transferred to the PMAs and that this roughness induced cell adhesive properties to the material. In particular, the topography facilitated immobilization of endothelial cells on the internal walls of the microwells. The authors also demonstrate that upon immobilization of endothelial cells to the microwells, a second population of cells, namely, pancreatic islets could be introduced, thus producing a 3D coculture platform.

A Feasibility Study of Processing Polydimethylsiloxane⁻Sodium Carboxymethylcellulose Composites by a Low-Cost Fused Deposition Modeling 3D Printer

Additive manufacturing (AM) techniques allow the construction of complex physical models reproducing the content of a specific CAD file, and, among them, Fused Deposition Molding (FDM) stands out for its many advantages. The aim of the present work is to perform a feasibility study of 3D printing of a model of human heart to be used to simulate surgical operations or for training through a two-step method based on extrusion and FDM processes. To this purpose, typical extrusion instrumentation and a simple and low-cost FDM printer are employed, in combination with a thermoplastic polydimethylsiloxane (PDMS), chosen for its transparency, flexibility, and high resistance to multiple agents and aging. To improve its tactile properties and mimic the slimy effect of living organs, sodium carboxymethylcellulose (Na⁻CMC) fibrils are added to it. The starting materials, the neat PDMS filament and the composite one, are deeply characterized in terms of structural, thermal, and rheological properties in order to fix the most suitable extrusion and FDM parameters. The composite filaments show larger diameter and roughness, which cause undesirable effects during 3D printing, such as episodic nozzle obstruction, and exhibit a faster degradation, making the FDM step difficult. Nevertheless, the major issues are related to the low crystallinity degree of the employed polymer. The feasibility study carried out leads to the printing of composite layers, even though far from the desired final target. Possible solutions to print the fully characterized Na⁻CMC/PDMS composite are addressed in the conclusion of this work.

3D-printed miniaturized fluidic tools in chemistry and biology

3D printing (3DP), an additive manufacturing (AM) approach allowing for rapid prototyping and decentralized fabrication on-demand, has become a common method for creating parts or whole devices. The wide scope of the AM extends from organized sectors of construction, ornament, medical, and R&D industries to individual explorers attributed to the low cost, high quality printers along with revolutionary tools and polymers. While progress is being made but big manufacturing challenges are still there. Considering the quickly shifting narrative towards miniaturized analytical systems (MAS) we focus on the development/rapid prototyping and manufacturing of MAS with 3DP, and application dependent challenges in engineering designs and choice of the polymeric materials and provide an exhaustive background to the applications of 3DP in biology and chemistry. This will allow readers to perceive the most important features of AM in creating (i) various individual and modular components, and (ii) complete integrated tools.