3D printed high density, reversible, chip-to-chip microfluidic interconnects

Leveraging the third dimension in microfluidic devices using 3D printing: no longer just scratching the surface

3D printers utilize cutting-edge technologies to create three-dimensional objects and are attractive tools for engineering compact microfluidic platforms with complex architectures for chemical and biochemical analyses. 3D printing's popularity is associated with the freedom of creating intricate designs using inexpensive instrumentation, and these tools can produce miniaturized platforms in minutes, facilitating fabrication scaleup. This work discusses key challenges in producing three-dimensional microfluidic structures using currently available 3D printers, addressing considerations about printer capabilities and software limitations encountered in the design and processing of new architectures. This article further communicates the benefits of using three-dimensional structures, including the ability to scalably produce miniaturized analytical systems and the possibility of combining them with multiple processes, such as mixing, pumping, pre-concentration, and detection. Besides increasing analytical applicability, such three-dimensional architectures are important in the eventual design of commercial devices since they can decrease user interferences and reduce the volume of reagents or samples required, making assays more reliable and rapid. Moreover, this manuscript provides insights into research directions involving 3D-printed microfluidic devices. Finally, this work offers an outlook for future developments to provide and take advantage of 3D microfluidic functionality in 3D printing. Graphical abstract Creating three-dimensional microfluidic structures using 3D printing will enable key advances and novel applications in (bio)chemical analysis.

Advanced manufacturing provides tailor-made solutions for crystallography with x-ray free-electron lasers

Serial crystallography at large facilities, such as x-ray free-electron lasers and synchrotrons, evolved as a powerful method for the high-resolution structural investigation of proteins that are critical for human health, thus advancing drug discovery and novel therapies. However, a critical barrier to successful serial crystallography experiments lies in the efficient handling of the protein microcrystals and solutions at microscales. Microfluidics are the obvious approach for any high-throughput, nano-to-microliter sample handling, that also requires design flexibility and rapid prototyping to deal with the variable shapes, sizes, and density of crystals. Here, we discuss recent advances in polymer 3D printing for microfluidics-based serial crystallography research and present a demonstration of emerging, large-scale, nano-3D printing approaches leading into the future of 3D sample environment and delivery device fabrication from liquid jet gas-dynamic virtual nozzles devices to fixed-target sample environment technology.

High-performance microchip electrophoresis separations of preterm birth biomarkers using 3D printed microfluidic devices

We employed digital light processing-stereolithography 3D printing to create microfluidic devices with different designs for microchip electrophoresis (µCE). Short or long straight channel, and two- or four-turn serpentine channel microfluidic devices with separation channel lengths of 1.3, 3.1, 3.0, and 4.7 cm, respectively, all with a cross injector design, were fabricated. We measured current as a function of time and voltage to determine a separation time window and conditions for the onset of Joule heating in these designs. Separations in these devices were evaluated by performing µCE and measuring theoretical plate counts for electric field strengths near and above the onset of Joule heating, with fluorescently labeled glycine and phenylalanine as model analytes. We further demonstrated µCE of peptides and proteins related to preterm birth risk, showing increased peak capacity and resolution compared to previous results with 3D printed microdevices. These results mark an important step forward in the use of 3D printed microfluidic devices for rapid bioanalysis by µCE.

Tunable resins with PDMS-like elastic modulus for stereolithographic 3D-printing of multimaterial microfluidic actuators

Stereolithographic 3D-printing (SLA) permits facile fabrication of high-precision microfluidic and lab-on-a-chip devices. SLA photopolymers often yield parts with low mechanical compliancy in sharp contrast to elastomers such as poly(dimethyl siloxane) (PDMS). On the other hand, SLA-printable elastomers with soft mechanical properties do not fulfill the distinct requirements for a highly manufacturable resin in microfluidics (e.g., high-resolution printability, transparency, low-viscosity). These limitations restrict our ability to print microfluidic actuators containing dynamic, movable elements. Here we introduce low-viscous photopolymers based on a tunable blend of the monomers poly(ethylene glycol) diacrylate (PEGDA, Mw ∼ 258) and the monoacrylate poly(ethylene glycol methyl ether) methacrylate (PEGMEMA, Mw ∼ 300). In these blends, which we term PEGDA-co-PEGMEMA, tuning the PEGMEMA content from 0% to 40% (v/v) alters the elastic modulus of the printed plastics by ∼400-fold, reaching that of PDMS. Through the addition of PEGMEMA, moreover, PEGDA-co-PEGMEMA retains desirable properties of highly manufacturable PEGDA such as low viscosity, solvent compatibility, cytocompatibility and low drug absorptivity. With PEGDA-co-PEGMEMA, we SLA-printed drastically enhanced fluidic actuators including microvalves, micropumps, and microregulators with a hybrid structure containing a flexible PEGDA-co-PEGMEMA membrane within a rigid PEGDA housing. These components were built using a custom "Print-Pause-Print" protocol, referred to as "3P-printing", that allows for fabricating high-resolution multimaterial parts with a desktop SLA printer without the need for post-assembly. SLA-printing of multimaterial microfluidic actuators addresses the unmet need of high-performance on-chip controls in 3D-printed microfluidic and lab-on-a-chip devices.

Biocompatible High-Resolution 3D-Printed Microfluidic Devices: Integrated Cell Chemotaxis Demonstration

We demonstrate a method to effectively 3D print microfluidic devices with high-resolution features using a biocompatible resin based on avobenzone as the UV absorber. Our method relies on spectrally shaping the 3D printer source spectrum so that it is fully overlapped by avobenzone's absorption spectrum. Complete overlap is essential to effectively limit the optical penetration depth, which is required to achieve high out-of-plane resolution. We demonstrate the high resolution in practice by 3D printing 15 μm square pillars in a microfluidic chamber, where the pillars are separated by 7.7 μm and are printed with 5 μm layers. Furthermore, we show reliable membrane valves and pumps using the biocompatible resin. Valves are tested to 1,000,000 actuations with no observable degradation in performance. Finally, we create a concentration gradient generation (CG) component and utilize it in two device designs for cell chemotaxis studies. The first design relies on an external dual syringe pump to generate source and sink flows to supply the CG channel, while the second is a complete integrated device incorporating on-chip pumps, valves, and reservoirs. Both device types are seeded with adherent cells that are subjected to a chemoattractant CG, and both show clear evidence of chemotactic cellular migration. Moreover, the integrated device demonstrates cellular migration comparable to the external syringe pump device. This demonstration illustrates the effectiveness of our integrated chemotactic assay approach and high-resolution biocompatible resin 3D printing fabrication process. In addition, our 3D printing process has been tuned for rapid fabrication, as printing times for the two device designs are, respectively, 8 and 15 min.

Vat photopolymerization 3D printed microfluidic devices for organ-on-a-chip applications

Organs-on-a-chip, or OoCs, are microfluidic tissue culture devices with micro-scaled architectures that repeatedly achieve biomimicry of biological phenomena. They are well positioned to become the primary pre-clinical testing modality as they possess high translational value. Current methods of fabrication have facilitated the development of many custom OoCs that have generated promising results. However, the reliance on microfabrication and soft lithographic fabrication techniques has limited their prototyping turnover rate and scalability. Additive manufacturing, known commonly as 3D printing, shows promise to expedite this prototyping process, while also making fabrication easier and more reproducible. We briefly introduce common 3D printing modalities before identifying two sub-types of vat photopolymerization - stereolithography (SLA) and digital light processing (DLP) - as the most advantageous fabrication methods for the future of OoC development. We then outline the motivations for shifting to 3D printing, the requirements for 3D printed OoCs to be competitive with the current state of the art, and several considerations for achieving successful 3D printed OoC devices touching on design and fabrication techniques, including a survey of commercial and custom 3D printers and resins. In all, we aim to form a guide for the end-user to facilitate the in-house generation of 3D printed OoCs, along with the future translation of these important devices.

Construction of Bone Hypoxic Microenvironment Based on Bone-on-a-Chip Platforms

The normal physiological activities and functions of bone cells cannot be separated from the balance of the oxygenation level, and the physiological activities of bone cells are different under different oxygenation levels. At present, in vitro cell cultures are generally performed in a normoxic environment, and the partial pressure of oxygen of a conventional incubator is generally set at 141 mmHg (18.6%, close to the 20.1% oxygen in ambient air). This value is higher than the mean value of the oxygen partial pressure in human bone tissue. Additionally, the further away from the endosteal sinusoids, the lower the oxygen content. It follows that the construction of a hypoxic microenvironment is the key point of in vitro experimental investigation. However, current methods of cellular research cannot realize precise control of oxygenation levels at the microscale, and the development of microfluidic platforms can overcome the inherent limitations of these methods. In addition to discussing the characteristics of the hypoxic microenvironment in bone tissue, this review will discuss various methods of constructing oxygen gradients in vitro and measuring oxygen tension from the microscale based on microfluidic technology. This integration of advantages and disadvantages to perfect the experimental study will help us to study the physiological responses of cells under more physiological-relevant conditions and provide a new strategy for future research on various in vitro cell biomedicines.

Recent developments in digital light processing 3D-printing techniques for microfluidic analytical devices

Digital light processing (DLP) 3D printing is rapidly advancing and has emerged as a powerful additive manufacturing approach to fabricate analytical microdevices. DLP 3D-printing utilizes a digital micromirror device to direct the projected light and photopolymerize a liquid resin, in a layer-by-layer approach. Advances in vat and lift design, projector technology, and resin composition, allow accurate fabrication of microchannel structures as small as 18 × 20 µm. This review describes the latest advances in DLP 3D-printing technology with respect to instrument set-up and resin formulation and highlights key efforts to fabricate microdevices targeting emerging (bio-)analytical chemistry applications, including colorimetric assays, extraction, and separation.

Chemistry in light-induced 3D printing

In the last few years, 3D printing has evolved from its original niche applications, such as rapid prototyping and hobbyists, towards many applications in industry, research and everyday life. This involved an evolution in terms of equipment, software and, most of all, in materials. Among the different available 3D printing technologies, the light activated ones need particular attention from a chemical point of view, since those are based on photocurable formulations and in situ rapid solidification via photopolymerization. In this article, the chemical aspects beyond the preparation of a formulation for light-induced 3D printing are analyzed and explained, aiming at giving more tools for the development of new photocurable materials that can be used for the fabrication of innovative 3D printable devices.

Graphical abstract

Surface Modification of 3D Printed Microfluidic Devices for Controlled Wetting in Two-Phase Flow

Microfluidic devices (MFDs) printed in 3-D geometry using digital light projection to polymerize monomers often have surfaces that are not as hydrophobic as MFDs made from polydimethylsiloxane. Droplet microfluidics in these types of devices are subject to droplet adhesion and aqueous spreading on less hydrophobic MFD surfaces. We have developed a post-processing technique using hydrophobic monomers that renders the surfaces of these devices much more hydrophobic. The technique is fast and easy, and involves flowing monomer without initiator into the channels and then exposing the entire device to UV light that generates radicals from the initiator molecules remaining in the original 3-D polymerization. After treatment the channels can be cleared and the surface is more hydrophobic, as evidenced by higher contact angles with aqueous droplets. We hypothesize that radicals generated near the previously printed surfaces initiate polymerization of the hydrophobic monomers on the surfaces without bulk polymerization extending into the channels. The most hydrophobic surfaces were produced by treatment with an alkyl acrylate and a fluorinated acrylate. This technique could be used for surface treatment with other types of monomers to impart unique characteristics to channels in MFDs.

3D Printed Platform for Impedimetric Sensing of Liquids and Microfluidic Channels

Fused deposition modeling 3D printing (FDM-3DP) employing electrically conductive filaments has recently been recognized as an exceptionally attractive tool for the manufacture of sensing devices. However, capabilities of 3DP electrodes to measure electric properties of materials have not yet been explored. To bridge this gap, we employ bimaterial FDM-3DP combining electrically conductive and insulating filaments to build an integrated platform for sensing conductivity and permittivity of liquids by impedance measurements. The functionality of the device is demonstrated by measuring conductivity of aqueous potassium chloride solution and bottled water samples and permittivity of water, ethanol, and their mixtures. We further implement an original idea of applying impedance measurements to investigate dimensions of 3DP channels as base structures of microfluidic devices, complemented by their optical microscopic analysis. We demonstrate that FDM-3DP allows the manufacture of microchannels of width down to 80 μm.

Microgaskets for High-Channel-Density Reconnectable Implantable Packaging

Demands for implantable bioelectronic devices to increase the number of channels for greater functional capacity and resolution, shrink implant size to minimize tissue response and patient burden, and support battery changes and electronics upgrades for long-term operational viability, cannot be met with existing implant-connector technology. In this paper we describe our novel approach to develop a rematable high-channel-density implant-connector technology, with a focus on the design, fabrication, and characterization of its microgasket. The microgaskets made of polydimethylsiloxane elastomer (PDMSe) have achieved much better electrical isolation for neural stimulation (~5 MΩ at 10 kHz) compared with conventional implant connectors (50 kΩ at 10 kHz), despite a 200-fold increase in channel density (conventional: ~0.0644 ch/mm², microgasket: ~12.8 ch/mm²). The microgaskets also achieved high electrical isolation for neural recording (i.e., ~35 MΩ at 1 kHz) at the same high channel density. When mechanically compressed the microscale vias in the PDMSe microgaskets deform laterally, which could damage or enhance gasket-traversing conductive spring elements in each microscale via depending on their design. We have demonstrated that by lowering the height-to-width aspect ratio of the gasket vias, they can maintain their shape under clamping pressures high enough to achieve high isolation.

Critical Study on the Tube-to-Chip Luer Slip Connectors

Luer slip is one of the gold standards for chip-to-world interface in microfluidics. They have outstanding mechanical and operational robustness in a broad range of applications using water and solvent-based liquids. Still, their main drawbacks are related to their size: they have relatively large dead volumes and require a significant footprint to assure a leak-free performance. Such aspects make their integration in systems with high microchannel density challenging. To date, there has been no geometrical optimization of the Luer slips to provide a solution to the mentioned drawbacks. This work aims to provide the rules toward downscaling the Luer slips. To this effect, seven variations of the Luer slip male connectors and five variations of Luer slip female connectors have been designed and manufactured focusing on the reduction of the size of connectors and minimization of the dead volumes. In all cases, female connectors have been developed to pair with the corresponding male connector. Characterization has been performed with a tailor-made test bench in which the closure force between male and female connectors has been varied between 7.9 and 55 N. For each applied closure force, the test bench allows liquid pressures to be tested between 0.5 and 2.0 bar. Finally, the analysis of a useful life determines the number of cycles that the connectors can withstand before leakage.

3D printed microfluidic device for automated, pressure-driven, valve-injected microchip electrophoresis of preterm birth biomarkers

A 3D printed, automated, pressure-driven injection microfluidic system for microchip electrophoresis (µCE) of preterm birth (PTB)-related peptides and proteins has been developed. Functional microvalves were formed, either with a membrane thickness of 5 µm and a layer exposure time of 450 ms or with a membrane thickness of 10 µm and layer exposure times of 300-350 ms. These valves allowed for control of fluid flow in device microchannels during sample injection for µCE separation. Device design and µCE conditions using fluorescently labeled amino acids were optimized. A sample injection time of 0.5 s and a separation voltage of 450 V (460 V/cm) yielded the best separation efficiency and resolution. We demonstrated the first µCE separation with pressure-driven injection in a 3D printed microfluidic device using fluorescently labeled PTB biomarkers and 532 nm laser excitation. Detection limits for two PTB biomarkers, peptide 1 and peptide 2, for an injection time of 1.5 s were 400 pM and 15 nM, respectively, and the linear detection range for peptide 2 was 50-400 nM. This 3D printed microfluidic system holds promise for future integration of on-chip sample preparation processes with µCE, offering promising possibilities for PTB risk assessment.

Recent Advances in Microfluidic Platform for Physical and Immunological Detection and Capture of Circulating Tumor Cells

CTCs (circulating tumor cells) are well-known for their use in clinical trials for tumor diagnosis. Capturing and isolating these CTCs from whole blood samples has enormous benefits in cancer diagnosis and treatment. In general, various approaches are being used to separate malignant cells, including immunomagnets, macroscale filters, centrifuges, dielectrophoresis, and immunological approaches. These procedures, on the other hand, are time-consuming and necessitate multiple high-level operational protocols. In addition, considering their low efficiency and throughput, the processes of capturing and isolating CTCs face tremendous challenges. Meanwhile, recent advances in microfluidic devices promise unprecedented advantages for capturing and isolating CTCs with greater efficiency, sensitivity, selectivity and accuracy. In this regard, this review article focuses primarily on the various fabrication methodologies involved in microfluidic devices and techniques specifically used to capture and isolate CTCs using various physical and biological methods as well as their conceptual ideas, advantages and disadvantages.

3D-printed microchip electrophoresis device containing spiral electrodes for integrated capacitively coupled contactless conductivity detection

In this work, we demonstrate for the first time the design and fabrication of microchip electrophoresis devices containing cross-shaped channels and spiral electrodes around the separation channel for microchip electrophoresis and capacitively coupled contactless conductivity detection. The whole device was prepared in a digital light processing-based 3D printer in poly(ethylene glycol) diacrylate resin. Outstanding X-Y resolution of the customized 3D printer ensured the fabrication of 40-μm cross section channels. The spiral channels were filled with melted gallium to form conductive electrodes around the separation channel. We demonstrate the applicability of the device on the separation of sodium, potassium, and lithium cations by microchip electrophoresis. Graphical abstract.

Binder-jetting 3D printer capable of voxel-based control over deposited ink volume, adaptive layer thickness, and selective multi-pass printing

The limited control over the printing process in commercial powder bed 3D printers hinders the exploration of novel materials and applications. In this study, a custom binder-jetting 3D printer was developed. The resulting fine-grained control over the printing process enables features such as voxel-based control over the printed ink volume, adaptive layer thickness, and selective multi-pass printing. A protocol was developed to optimize the 3D printing process for new build materials and binders, in which resolution tests were used as a guideline for improving the dimensional accuracy. As a demonstration of the voxel-based control over the printing process, a functionally graded object was printed.

Determination of total protein content in biomedical products by the PDMS-assisted lab-in-a-syringe assay using 3D printed scaffolds removal

The aim of our work was to develop a low-cost, portable device for the fast and easy determination of total protein content by using PDMS-based lab-in-a-syringe technology with removal of 3D-printed channels. We proposed two designs with a one-step PDMS curing and a two-step PDMS-curing fabrication procedure. The one-step PDMS microdevices were found to be the best in the view of preparation, repeatability, and stability of the reagent. This design was then applied for the determination of total protein content in biomedical products using the Bradford assay.

Spatially and optically tailored 3D printing for highly miniaturized and integrated microfluidics

Traditional 3D printing based on Digital Light Processing Stereolithography (DLP-SL) is unnecessarily limiting as applied to microfluidic device fabrication, especially for high-resolution features. This limitation is due primarily to inherent tradeoffs between layer thickness, exposure time, material strength, and optical penetration that can be impossible to satisfy for microfluidic features. We introduce a generalized 3D printing process that significantly expands the accessible spatially distributed optical dose parameter space to enable the fabrication of much higher resolution 3D components without increasing the resolution of the 3D printer. Here we demonstrate component miniaturization in conjunction with a high degree of integration, including 15 μm × 15 μm valves and a 2.2 mm × 1.1 mm 10-stage 2-fold serial diluter. These results illustrate our approach's promise to enable highly functional and compact microfluidic devices for a wide variety of biomolecular applications.

Post-fabrication tuning of microring resonators using 3D-printed microfluidics

We demonstrate a method of tuning the resonant frequencies of silicon microring resonators using a 3D-printed microfluidic chip overlaid directly on the photonic circuit with zero energy consumption following the initial tuning. Aqueous solutions with different concentrations of NaCl are used in experimentation. A shift of a full free spectral range is observed at a concentration of 10% NaCl. On a 60 µm microring resonator, this equals a resonant wavelength shift of 1.514 nm when the index of the cladding changes by 0.017 refractive index units (RIUs), or at a rate of 89.05 nm/RIU.

Characterization and Evaluation of 3D-Printed Connectors for Microfluidics

3D printing is regarded as a useful tool for the fabrication of microfluidic connectors to overcome the challenges of time consumption, clogging, poor alignment and bulky fixtures existing for current interconnections. 3D-printed connectors without any additional components can be directly printed to substrate with an orifice by UV-assisted coaxial printing. This paper further characterized and evaluated 3D-printed connectors fabricated by the proposed method. A process window with an operable combination of flow rates was identified. The outer flow rate could control the inner channel dimensions of 3D-printed connectors, which were expected to achieve less geometric mismatch of flow paths in microfluidic interfaces. The achieved smallest inner channel diameter was around 120 µm. Furthermore, the withstood pressure of 3D-printed connectors was evaluated to exceed 450 kPa, which could enable microfluidic chips to work at normal pressure.

[Research advances of high-throughput cell-based drug screening systems based on microfluidic technique]

Drug screening is the process of screening new drugs or leading compounds with biological activity from natural products or synthetic compounds, and it plays an essential role in drug discovery. The discovery of innovative drugs requires the screening of a large number of compounds with appropriate drug targets. With the development of genomics, proteomics, metabolomics, combinatorial chemistry, and other disciplines, the library of drug molecules has been largely expanded, and the number of drug targets is continuously increasing. High-throughput screening systems enable the parallel analysis of thousands of reactions through automated operation, thereby enhancing the experimental scale and efficiency of drug screening. Among them, cell-based high-throughput drug screening has become the main screening mode because it can provide a microenvironment similar to human physiological conditions. However, the current high-throughput screening systems are mainly built based on multiwell plates, which have several disadvantages such as simple cell culture conditions, laborious and time-consuming operation, and high reagent consumption. In addition, it is difficult to achieve complex drug combination screening. Therefore, there is an urgent need for rapid and low-cost drug screening methods to reduce the time and cost of drug development. Microfluidic techniques, which can manipulate and control microfluids in microscale channels, have the advantages of low consumption, high efficiency, high throughput, and automation. It can overcome the shortcomings of screening systems based on multi-well plates and provide an efficient and reliable technical solution for establishing high-throughput cell-based screening systems. Moreover, microfluidic systems can be flexibly changed in terms of cell culture materials, chip structure design, and fluid control methods to enable better control and simulation of cell growth microenvironment. Operations such as cell seeding, culture medium replacement or addition, drug addition and cleaning, and cell staining reagent addition are usually involved in cell-based microfluidic screening systems. These operations are all based on the manipulation of microfluids. This paper reviews the research advances in cell-based microfluidic screening systems using different microfluidic manipulation modes, namely perfusion flow mode, droplet mode, and microarray mode. In addition, the advantages and disadvantages of these systems are summarized. Moreover, the development prospects of high-throughput screening systems based on microfluidic techniques has been looked forward. Furthermore, the current problems in this field and the directions to overcome these problems are discussed.

Low-cost and open-source strategies for chemical separations

In recent years, a trend toward utilizing open access resources for laboratory research has begun. Open-source design strategies for scientific hardware rely upon the use of widely available parts, especially those that can be directly printed using additive manufacturing techniques and electronic components that can be connected to low-cost microcontrollers. Open-source software eliminates the need for expensive commercial licenses and provides the opportunity to design programs for specific needs. In this review, the impact of the "open-source movement" within the field of chemical separations is described, primarily through a comprehensive look at research in this area over the past five years. Topics that are covered include general laboratory equipment, sample preparation techniques, separations-based analysis, detection strategies, electronic system control, and software for data processing. Remaining hurdles and possible opportunities for further adoption of open-source approaches in the context of these separations-related topics are also discussed.

3D-Printed Microfluidic Droplet Generator with Hydrophilic and Hydrophobic Polymers

Droplet generation has been widely used in conventional two-dimensional (2D) microfluidic devices, and has recently begun to be explored for 3D-printed droplet generators. A major challenge for 3D-printed devices is preventing water-in-oil droplets from sticking to the interior surfaces of the droplet generator when the device is not made from hydrophobic materials. In this study, two approaches were investigated and shown to successfully form droplets in 3D-printed microfluidic devices. First, several printing resin candidates were tested to evaluate their suitability for droplet formation and material properties. We determined that a hexanediol diacrylate/lauryl acrylate (HDDA/LA) resin forms a solid polymer that is sufficiently hydrophobic to prevent aqueous droplets (in a continuous oil flow) from attaching to the device walls. The second approach uses a fully 3D annular channel-in-channel geometry to form microfluidic droplets that do not contact channel walls, and thus, this geometry can be used with hydrophilic resins. Stable droplets were shown to form using the channel-in-channel geometry, and the droplet size and generation frequency for this geometry were explored for various flow rates for the continuous and dispersed phases.

Pixel-based open-space microfluidics for versatile surface processing

An increasing number of applications in biology, chemistry, and material sciences require fluid manipulation beyond what is possible with current automated pipette handlers, such as gradient generation, interface reactions, reagent streaming, and reconfigurability. In this article, we introduce the pixelated chemical display (PCD), a scalable strategy for highly parallel, reconfigurable liquid handling on open surfaces. Microfluidic "pixels" are created when a fluid stream injected above a surface is confined by neighboring identical fluid streams, forming a repeatable flow unit that can be used to tesselate a surface. PCDs generating up to 144 pixels are fabricated and used to project "chemical moving pictures" made of several reagents over both immersed and dry surfaces, without any physical barrier or wall. This work distinguishes itself from previous work in open-space microfluidics by presenting a device architecture where the number of confinement areas can be scaled to any size. Furthermore, it challenges the open-space tenet that the aspiration rate must be higher than the injection rate for reagents to be confined. Overall, this article sets the foundation for massively parallel surface processing using continuous flow streams and showcases possibilities in both wet and dry surface patterning and roll-to-roll processes.

Trace multi-class organic explosives analysis in complex matrices enabled using LEGO®-inspired clickable 3D-printed solid phase extraction block arrays

The development of a new, lower cost method for trace explosives recovery from complex samples is presented using miniaturised, click-together and leak-free 3D-printed solid phase extraction (SPE) blocks. For the first time, a large selection of ten commercially available 3D printing materials were comprehensively evaluated for practical, flexible and multiplexed SPE using stereolithography (SLA), PolyJet and fused deposition modelling (FDM) technologies. Miniaturised single-piece, connectable and leak-free block housings inspired by Lego® were 3D-printed in a methacrylate-based resin, which was found to be most stable under different aqueous/organic solvent and pH conditions, using a cost-effective benchtop SLA printer. Using a tapered SPE bed format, frit-free packing of multiple different commercially available sorbent particles was also possible. Coupled SPE blocks were then shown to offer efficient analyte enrichment and a potentially new approach to improve the stability of recovered analytes in the field when stored on the sorbent, rather than in wet swabs. Performance was measured using liquid chromatography-high resolution mass spectrometry and was better, or similar, to commercially available coupled SPE cartridges, with respect to recovery, precision, matrix effects, linearity and range, for a selection of 13 peroxides, nitramines, nitrate esters and nitroaromatics. Mean % recoveries from dried blood, oil residue and soil matrices were 79 ± 24%, 71 ± 16% and 76 ± 24%, respectively. Excellent detection limits between 60 fg for 3,5-dinitroaniline to 154 pg for nitroglycerin were also achieved across all matrices. To our knowledge, this represents the first application of 3D printing to SPE of so many organic compounds in complex samples. Its introduction into this forensic method offered a low-cost, 'on-demand' solution for selective extraction of explosives, enhanced flexibility for multiplexing/design alteration and potential application at-scene.

Microfluidic gasketless interconnects sealed by superhydrophobic surfaces

Existing methods for sealing chip-to-chip (or module-to-motherboard) microfluidic interconnects commonly use additional interconnect components (O-rings, gaskets, and tubing), and manual handling expertise for assembly. Novel gasketless superhydrophobic fluidic interconnects (GSFIs) sealed by transparent superhydrophobic surfaces, forming liquid bridges between the fluidic ports for fluidic passages were demonstrated. Two test platforms were designed, fabricated, and evaluated, a multi-port chip system (ten interconnects) and a modules-on-a-motherboard system (four interconnects). System assembly in less than 3 sec was done by embedded magnets and pin-in-V-groove structures. Flow tests with deionized (DI) water, ethanol/water mixture, and plasma confirmed no leakage through the gasketless interconnects up to a maximum flow rate of 100 μL/min for the multi-port chip system. The modules-on-a-motherboard system showed no leakage of water at a flow rate of 20 μL/min and a pressure drop of 3.71 psi. Characterization of the leakage pressure as a function of the surface tension of the sample liquid in the multi-port chip system revealed that lower surface tension of the liquid led to lower static water contact angles on the superhydrophobic-coated substrate and lower leakage pressures. The high-density, rapidly assembled, gasketless interconnect technology will open up new avenues for chip-to-chip fluid transport in complex microfluidic modular systems.

Digital Manufacturing for Microfluidics

The microfluidics field is at a critical crossroads. The vast majority of microfluidic devices are presently manufactured using micromolding processes that work very well for a reduced set of biocompatible materials, but the time, cost, and design constraints of micromolding hinder the commercialization of many devices. As a result, the dissemination of microfluidic technology-and its impact on society-is in jeopardy. Digital manufacturing (DM) refers to a family of computer-centered processes that integrate digital three-dimensional (3D) designs, automated (additive or subtractive) fabrication, and device testing in order to increase fabrication efficiency. Importantly, DM enables the inexpensive realization of 3D designs that are impossible or very difficult to mold. The adoption of DM by microfluidic engineers has been slow, likely due to concerns over the resolution of the printers and the biocompatibility of the resins. In this article, we review and discuss the various printer types, resolution, biocompatibility issues, DM microfluidic designs, and the bright future ahead for this promising, fertile field.

3D Printed Microfluidics

Traditional microfabrication techniques suffer from several disadvantages, including the inability to create truly three-dimensional (3D) architectures, expensive and time-consuming processes when changing device designs, and difficulty in transitioning from prototyping fabrication to bulk manufacturing. 3D printing is an emerging technique that could overcome these disadvantages. While most 3D printed fluidic devices and features to date have been on the millifluidic size scale, some truly microfluidic devices have been shown. Currently, stereolithography is the most promising approach for routine creation of microfluidic structures, but several approaches under development also have potential. Microfluidic 3D printing is still in an early stage, similar to where polydimethylsiloxane was two decades ago. With additional work to advance printer hardware and software control, expand and improve resin and printing material selections, and realize additional applications for 3D printed devices, we foresee 3D printing becoming the dominant microfluidic fabrication method.

Electrical Isolation Performance of Microgasket Technology for Implant Packaging

High-channel-count neural interfaces are typically packaged by being permanently bonded to their packaged electronics followed by encapsulation. Such interfaces are often intimately integrated into neural tissue, their removal to replace the battery or upgrade electronics is not undesirable. Gaskets are widely used to provide liquid/electrical isolation and to seal the connection between two or more mating parts. Pressure-driven microgaskets are well established in the field of microfluidics. Although rematable microgaskets for fluidic interconnects exist, the use of microgaskets for electrical isolation have not been demonstrated. Our approach is to electrically isolate 2-D arrays of contact pads using a compressible silicone microgasket. Electrochemical impedance spectroscopy (EIS) was used to quantify the electrical isolation of the microgasket on contact pads, which were formed in a polyimide flex circuit, as a function of frequency after being soaked in saline. Experiments have shown that the compressed sub-millimeter PDMSe microgasket can provide excellent isolation (i.e., >30 MΩ at 1 KHz) that is comparable to the other more conventional packaging methods, such as encapsulation in polydimethylsiloxane elastomer (PDMSe) or parylene-C. Our microgasket-based approach should be scalable to high channel counts and high channel densities enabling much smaller and higher-performance neural implants.

Self-Sustaining 3D Thin Liquid Films in Ambient Environments

Thin liquid films (TLF) have fundamental and technological importance ranging from the thermodynamics of cell membranes to the safety of light-water cooled nuclear reactors. The creation of stable water TLFs, however, is very difficult. In this paper, the realization of thin liquid films of water with custom 3D geometries that persist indefinitely in ambient environments is reported. The wetting films are generated using microscale "mounts" fed by microfluidic channels with small feature sizes and large aspect ratios. These devices are fabricated with a custom 3D printer and resin, which were developed to print high resolution microfluidic geometries as detailed in Reference 26. By modifying the 3D-printed polymer to be hydrophilic and taking advantage of well-known wetting principles and capillary effects, self-sustaining microscale "water fountains" are constructed that continuously replenish water lost to evaporation while relying on surface tension to stabilize their shape. To the authors' knowledge, this is the first demonstration of stable sub-micron thin liquid films (TLFs) of pure water on curved 3D geometries.

Biocompatible PEGDA Resin for 3D Printing

We report a non-cytotoxic resin compatible with and designed for use in custom high-resolution 3D printers that follow the design approach described in Gong et al., Lab Chip 17, 2899 (2017). The non-cytotoxic resin is based on a poly(ethylene glycol) diacrylate (PEGDA) monomer with avobenzone as the UV absorber instead of 2-nitrophenyl phenyl sulfide (NPS). Both NPS-PEGDA and avobenzone-PEGDA (A-PEGDA) resins were evaluated for cytotoxicity and cell adhesion. We show that NPS-PEGDA can be made effectively non-cytotoxic with a post-print 12-hour ethanol wash, and that A-PEGDA, as-printed, is effectively non-cytotoxic. 3D prints made with either resin do not support strong cell adhesion in their as-printed state; however, cell adhesion increases dramatically with a short plasma treatment. Using A-PEGDA, we demonstrate spheroid formation in ultra-low adhesion 3D printed wells, and cell migration from spheroids on plasma-treated adherent surfaces. Given that A-PEGDA can be 3D printed with high resolution, it has significant promise for a wide variety of cell-based applications using 3D printed microfluidic structures.

A compact LED-based projection microstereolithography for producing 3D microstructures

Projection microstereolithography (PµSL) is a promising additive manufacturing technique due to its low cost, accuracy, speed, and also the diversity of the materials that it can use. Recently it has shown great potentials in various applications such as microfluidics, tissue engineering, micro-optics, biomedical microdevices, and so on. However, studies on PµSL are still ongoing in terms of the quality and accuracy of the construction process, which particularly affect the fabrication of complex 3D microstructures and make it attractive enough to be considered for commercial applications. In this paper, a compact LED-based PµSL 3D printer for the fabrication of 3D microstructures was developed, and the effective parameters that influence the quality of construction were thoroughly investigated and optimized. Accordingly, a customized optical system, including illumination optics and projection optics, was designed using optical engineering principles. This custom 3D printer was proposed for the PµSL process, which besides improving the quality of construction, led to the reduction of the size of the device, its cost-effectiveness, and the repeatability of its performance. To demonstrate the performance of the fabricated device, a variety of complex 3D microstructures such as porous, hollow, helical, and self-support microstructures were constructed. In addition, the repeatability of the device was assessed by fabricating microstructure arrays. The device performance showed that the lateral accuracy of printing was better than 5 μm, and the smallest thickness of the printed layer was 1 μm. Moreover, the maximum printable size of the device was 6.4 mm × 4 mm × 40 mm.

3D Printed Microfluidic Devices for Microchip Electrophoresis of Preterm Birth Biomarkers

This work demonstrates for the first time the creation of microchip electrophoresis devices with ∼50 μm cross-sectional dimensions by stereolithographic 3D printing and their application in the analysis of medically significant biomarkers related to risk for preterm birth (PTB). We determined that device current was linear with applied potential up to 800 V (620 V/cm). We optimized device and separation conditions using fluorescently labeled amino acids as a model system and compared the performance in our 3D printed microfluidic devices to that in other device materials commonly used for microchip electrophoresis analysis. We demonstrated for the first time microchip electrophoresis in a 3D printed device of three PTB biomarkers, including peptides and a protein, with suitable separation characteristics. Limits of detection for microchip electrophoresis in 3D printed microfluidic devices were also determined for PTB biomarkers to be in the high picomolar to low nanomolar range.

Current and Emerging Technologies for the Detection of Norovirus from Shellfish

Reports of norovirus infections associated with the consumption of contaminated bivalve molluscan shellfish negatively impact both consumers and commercial shellfish operators. Current virus recovery and PCR detection methods can be expensive and time consuming. Due to the lack of rapid, user-friendly and onsite/infield methods, it has been difficult to establish an effective virus monitoring regime that is able to identify contamination points across the production line (i.e., farm-to-plate) to ensure shellfish quality. The focus of this review is to evaluate current norovirus detection methods and discuss emerging approaches. Recent advances in omics-based detection approaches have the potential to identify novel biomarkers that can be incorporated into rapid detection kits for onsite use. Furthermore, some omics techniques have the potential to simultaneously detect multiple enteric viruses that cause human disease. Other emerging technologies discussed include microfluidic, aptamer and biosensor-based detection methods developed to detect norovirus with high sensitivity from a simple matrix. Many of these approaches have the potential to be developed as user-friendly onsite detection kits with minimal costs. However, more collaborative efforts on research and development will be required to commercialize such products. Once developed, these emerging technologies could provide a way forward that minimizes public health risks associated with shellfish consumption.

Microfluidic multipoles theory and applications

Microfluidic multipoles (MFMs) have been realized experimentally and hold promise for "open-space" biological and chemical surface processing. Whereas convective flow can readily be predicted using hydraulic-electrical analogies, the design of advanced microfluidic multipole is constrained by the lack of simple, accurate models to predict mass transport within them. In this work, we introduce the complete solutions to mass transport in multipolar microfluidics based on the iterative conformal mapping of 2D advection-diffusion around a simple edge into dipoles and multipolar geometries, revealing a rich landscape of transport modes. The models are validated experimentally with a library of 3D printed devices and found in excellent agreement. Following a theory-guided design approach, we further ideate and fabricate two classes of spatiotemporally reconfigurable multipolar devices that are used for processing surfaces with time-varying reagent streams, and to realize a multistep automated immunoassay. Overall, the results set the foundations for exploring, developing, and applying open-space microfluidic multipoles.

Integrated Printed Microfluidic Biosensors

Integrated printed microfluidic biosensors are one of the most recent point-of-care (POC) sensor developments. Fast turnaround time for production and ease of customization, enabled by the integration of recognition elements and transducers, are key for on-site biosensing for both healthcare and industry and for speeding up translation to real-life applications. Here, we provide an overview of recent progress in printed microfluidics, from the 2D to the 4D level, accompanied by novel sensing element integration. We also explore the latest trends in integrated printed microfluidics for healthcare, especially POC diagnostics, and food safety applications.

Rapid and Inexpensive Fabrication of Multi-Depth Microfluidic Device using High-Resolution LCD Stereolithographic 3D Printing

With the dramatic increment of complexity, more microfluidic devices require 3D structures, such as multi-depth and -layer channels. The traditional multi-step photolithography is time-consuming and labor-intensive and also requires precise alignment during the fabrication of microfluidic devices. Here, we present an inexpensive, single-step, and rapid fabrication method for multi-depth microfluidic devices using a high-resolution liquid crystal display (LCD) stereolithographic (SLA) three-dimensional (3D) printing system. With the pixel size down to 47.25 μm, the feature resolutions in the horizontal and vertical directions are 150 μm and 50 μm, respectively. The multi-depth molds were successfully printed at the same time and the multi-depth features were transferred properly to the polydimethylsiloxane (PDMS) having multi-depth channels via soft lithography. A flow-focusing droplet generator with a multi-depth channel was fabricated using the presented 3D printing method. Experimental results show that the multi-depth channel could manipulate the morphology and size of droplets, which is desired for many engineering applications. Taken together, LCD SLA 3D printing is an excellent alternative method to the multi-step photolithography for the fabrication of multi-depth microfluidic devices. Taking the advantages of its controllability, cost-effectiveness, and acceptable resolution, LCD SLA 3D printing can have a great potential to fabricate 3D microfluidic devices.

3D printed selectable dilution mixer pumps

In this paper, we demonstrate the ability to 3D print tightly integrated structures with active valves, pumps, and mixers, and we use our compact chip-to-chip interconnects [Gong et al., Lab Chip 18, 639-647 (2018)] to move bulky world-to-chip connections to separate interface chips for both post-print flushing and post-cure device operation. As example devices, we first examine 3D printed pumps, followed by two types of selectable ratio mixer pumps, a linear dilution mixer pump (LDMP) and a parallelized dilution mixer pump (PDMP), which occupy volumes of only 1.5 mm 3 and 2.6 mm 3 , respectively. The LDMP generates a selectable dilution ratio from a linear set of possibilities, while the PDMP generates a denser set of possible dilutions with a maximum dilution ratio of 1/16. The PDMP also incorporates a new 4-to-1 valve to simultaneously control 4 inlet channels. To characterize LDMP and PDMP operation and performance, we present a new, low-cost video method to directly measure the relative concentration of an absorptive dye on a pixel-by-pixel basis for each video frame. Using this method, we find that 6 periods of the active mixer that forms the core of the LDMP and PDMP are sufficient to fully mix the fluid, and that the generated concentrations track the designed dilution ratios as expected. The LDMP mixes 20 nl per 4.6 s mixer pump period, while the PDMP uses parallelized input pumps to process the same fluid volume with greater choice of dilution ratios in a 3.6 s period.

3D printed microfluidic devices with immunoaffinity monoliths for extraction of preterm birth biomarkers

Preterm birth (PTB) is defined as birth before the 37th week of pregnancy and results in 15 million early deliveries worldwide every year. Presently, there is no clinical test to determine PTB risk; however, a panel of nine biomarkers found in maternal blood serum has predictive power for a subsequent PTB. A significant step in creating a clinical diagnostic for PTB is designing an automated method to extract and purify these biomarkers from blood serum. Here, microfluidic devices with 45 μm × 50 μm cross-section channels were 3D printed with a built-in polymerization window to allow a glycidyl methacrylate monolith to be site-specifically polymerized within the channel. This monolith was then used as a solid support to attach antibodies for PTB biomarker extraction. Using these functionalized monoliths, it was possible to selectively extract a PTB biomarker, ferritin, from buffer and a human blood serum matrix. This is the first demonstration of monolith formation in a 3D printed microfluidic device for immunoaffinity extraction. Notably, this work is a crucial first step toward developing a 3D printed microfluidic clinical diagnostic for PTB risk.

A 96-well microplate bioreactor platform supporting individual dual perfusion and high-throughput assessment of simple or biofabricated 3D tissue models

Traditional 2D monolayer cell cultures and submillimeter 3D tissue construct cultures used widely in tissue engineering are limited in their ability to extrapolate experimental data to predict in vivo responses due to their simplistic organization and lack of stimuli. The rise of biofabrication and bioreactor technologies has sought to address this through the development of techniques to spatially organize components of a tissue construct, and devices to supply these tissue constructs with an increasingly in vivo-like environment. Current bioreactors supporting both parenchymal and barrier tissue constructs in interconnected systems for body-on-a-chip platforms have chosen to emphasize study throughput or system/tissue complexity. Here, we report a platform to address this disparity in throughput and both system complexity (by supporting multiple in situ assessment methods) and tissue complexity (by adopting a construct-agnostic format). We introduce an ANSI/SLAS-compliant microplate and docking station fabricated via stereolithography (SLA), or precision machining, to provide up to 96 samples (Ø6 × 10 mm) with two individually-addressable fluid circuits (192 total), loading access, and inspection window for imaging during perfusion. Biofabricated ovarian cancer models were developed to demonstrate the in situ assessment capabilities via microscopy and a perfused resazurin-based metabolic activity assay. In situ microscopy highlighted flexibility of the sample housing to accommodate a range of sample geometries. Utility for drug screening was demonstrated by exposing the ovarian cancer models to an anticancer drug (doxorubicin) and generating the dose-response curve in situ, while achieving an assay quality similar to static wellplate culture. The potential for quantitative analysis of temporal tissue development and screening studies was confirmed by imaging soft- (gelatin) and hard-tissue (calcium chloride) analogs inside the bioreactor via spectral computed tomography (CT) scanning. As a proof-of-concept for particle tracing studies, flowing microparticles were visualized to inform the design of hydrogel constructs. Finally, the ability for mechanistic yet high-throughput screening was demonstrated in a vascular coculture model adopting endothelial and mesenchymal stem cells (HUVEC-MSC), encapsulated in gelatin-norbornene (gel-NOR) hydrogel cast into SLA-printed well inserts. This study illustrates the potential of a scalable dual perfusion bioreactor platform for parenchymal and barrier tissue constructs to support a broad range of multi-organ-on-a-chip applications.

3D Printed Microfluidic Features Using Dose Control in X, Y, and Z Dimensions

Interest has grown in recent years to leverage the possibilities offered by three-dimensional (3D) printing, such as rapid iterative changes; the ability to more fully use 3D device volume; and ease of fabrication, especially as it relates to the creation of complex microfluidic devices. A major shortcoming of most commercially available 3D printers is that their resolution is not sufficient to produce features that are truly microfluidic (<100 × 100 μm²). Here, we test a custom 3D printer for making ~30 μm scale positive and negative surface features, as well as positive and negative features within internal voids (i.e., microfluidic channels). We found that optical dosage control is essential for creating the smallest microfluidic features (~30 µm wide for ridges, ~20 µm wide for trenches), and that this resolution was achieved for a number of different exposure approaches. Additionally, we printed various microfluidic particle traps, showed capture of 25 µm diameter polymer beads, and iteratively improved the trap design. The rapid feedback allowed by 3D printing, as well as the ability to carefully control optical exposure conditions, should lead to new innovations in the types and sizes of devices that can be created for microfluidics.

Microchip electrophoresis separation of a panel of preterm birth biomarkers

Preterm birth (PTB) is responsible for over one million infant deaths annually worldwide. Often, the first and only indication of PTB risk is the onset of early labor. Thus, there is an urgent need for an early PTB risk diagnostic that is inexpensive, reliable, and robust. Here, we describe the development of a microchip electrophoresis (μCE) method for separating a mixture of six PTB protein and peptide biomarkers present in maternal blood serum. μCE devices were photografted with a poly(ethylene glycol) diacrylate surface coating to regulate EOF and reduce nonspecific analyte adsorption. Separation conditions including buffer pH, buffer concentration, and applied electric field were varied to improve biomarker peak resolution while minimizing deleterious effects like Joule heating. In this way, it was possible to separate six PTB biomarkers, the first μCE separation of this biomarker panel. LODs were also measured for each of the six PTB biomarkers. In the future, this μCE separation can be integrated with upstream maternal blood serum sample preparation steps to yield a complete PTB risk diagnosis microdevice.