A microfluidic chip with double-sided herringbone microstructures for enhanced capture of rare tumor cells

Study on the Flow Field Distribution in Microfluidic Cells for Surface Plasmon Resonance Array Detection

This research is dedicated to optimizing the design of microfluidic cells to minimize mass transfer effects and ensure a uniform flow field distribution, which is essential for accurate SPR array detection. Employing finite element simulations, this study methodically explored the internal flow dynamics within various microfluidic cell designs to assess the impact of different contact angles on flow uniformity. The cells, constructed from Polydimethylsiloxane (PDMS), were subjected to micro-particle image velocimetry to measure flow velocities in targeted sections. The results demonstrate that a contact angle of 135° achieves the most uniform flow distribution, significantly enhancing the capability for high-throughput array detection. While the experimental results generally corroborated the simulations, minor deviations were observed, likely due to fabrication inaccuracies. The microfluidic cells, evaluated using a custom-built SPR system, showed consistent repeatability.

Conductive Nanofibers-Enhanced Microfluidic Device for the Efficient Capture and Electrical Stimulation-Triggered Rapid Release of Circulating Tumor Cells

The effective detection and release of circulating tumor cells (CTCs) are of great significance for cancer diagnosis and monitoring. The microfluidic technique has proved to be a promising method for CTCs isolation and subsequent analysis. However, complex micro-geometries or nanostructures were often constructed and functionalized to improve the capture efficiency, which limited the scale-up for high-throughput production and larger-scale clinical applications. Thus, we designed a simple conductive nanofiber chip (CNF-Chip)-embedded microfluidic device with a herringbone microchannel to achieve the efficient and specific capture and electrical stimulation-triggered rapid release of CTCs. Here, the most used epithelial cell adhesion molecule (EpCAM) was selected as the representative biomarker, and the EpCAM-positive cancer cells were mainly studied. Under the effects of the nanointerface formed by the nanofibers with a rough surface and the herringbone-based high-throughput microfluidic mixing, the local topographic interaction between target cells and nanofibrous substrate in the microfluidic was synergistically enhanced, and the capture efficiency for CTCs was further improved (more than 85%). After capture, the sensitive and rapid release of CTCs (release efficiency above 97%) could be conveniently achieved through the cleavage of the gold-sulfur bond by applying a low voltage (-1.2 V). The device was successfully used for the effective isolation of CTCs in clinical blood samples from cancer patients, indicating the great potential of this CNF-Chip-embedded microfluidic device in clinical applications.

Recent Advances in Methods for Circulating Tumor Cell Detection

Circulating tumor cells (CTCs) are released from primary tumors and transported through the body via blood or lymphatic vessels before settling to form micrometastases under suitable conditions. Accordingly, several studies have identified CTCs as a negative prognostic factor for survival in many types of cancer. CTCs also reflect the current heterogeneity and genetic and biological state of tumors; so, their study can provide valuable insights into tumor progression, cell senescence, and cancer dormancy. Diverse methods with differing specificity, utility, costs, and sensitivity have been developed for isolating and characterizing CTCs. Additionally, novel techniques with the potential to overcome the limitations of existing ones are being developed. This primary literature review describes the current and emerging methods for enriching, detecting, isolating, and characterizing CTCs.

Herringbone micromixers for particle filtration

Herringbone micromixers are a powerful tool for introducing advection into microfluidic systems. While these mixers are typically used for mixing fluids faster than the rate of diffusion, there has been recent interest in using the device to enhance interactions between suspended particles and channel walls. We show how the common approximations applied to herringbone micromixer theory can have a significant impact on results. We show that the inclusion of gravity can greatly alter the interaction probability between suspended particles and channel walls. We also investigate the proposed impedance matching condition and the inclusion of imperfect binding using numerical methods, and investigate transient behaviors using an experimental system. These results indicate that while traditional methods, such as simple streamline analysis, remain powerful tools, it should not be considered predictive in the general case.

In-situ transfer vat photopolymerization for transparent microfluidic device fabrication

While vat photopolymerization has many advantages over soft lithography in fabricating microfluidic devices, including efficiency and shape complexity, it has difficulty achieving well-controlled micrometer-sized (smaller than 100 μm) channels in the layer building direction. The considerable light penetration depth of transparent resin leads to over-curing that inevitably cures the residual resin inside flow channels, causing clogs. In this paper, a 3D printing process — in-situ transfer vat photopolymerization is reported to solve this critical over-curing issue in fabricating microfluidic devices. We demonstrate microchannels with high Z-resolution (within 10 μm level) and high accuracy (within 2 μm level) using a general method with no requirements on liquid resins such as reduced transparency nor leads to a reduced fabrication speed. Compared with all other vat photopolymerization-based techniques specialized for microfluidic channel fabrication, our universal approach is compatible with commonly used 405 nm light sources and commercial photocurable resins. The process has been verified by multifunctional devices, including 3D serpentine microfluidic channels, microfluidic valves, and particle sorting devices. This work solves a critical barrier in 3D printing microfluidic channels using the high-speed vat photopolymerization process and broadens the material options. It also significantly advances vat photopolymerization’s use in applications requiring small gaps with high accuracy in the Z-direction.

Despite many advantages of vat photopolymerization in microfluidic device fabrication, well-controlled μm-sized (< 100 μm) channels in the layer building direction remains a challenge. Here, authors present a general high resolution and low-cost 3D printing process that can produce devices within the 10 μm scale.

Geometric structure design of passive label-free microfluidic systems for biological micro-object separation

Passive and label-free microfluidic devices have no complex external accessories or detection-interfering label particles. These devices are now widely used in medical and bioresearch applications, including cell focusing and cell separation. Geometric structure plays the most essential role when designing a passive and label-free microfluidic chip. An exquisitely designed geometric structure can change particle trajectories and improve chip performance. However, the geometric design principles of passive and label-free microfluidics have not been comprehensively acknowledged. Here, we review the geometric innovations of several microfluidic schemes, including deterministic lateral displacement (DLD), inertial microfluidics (IMF), and viscoelastic microfluidics (VEM), and summarize the most creative innovations and design principles of passive and label-free microfluidics. We aim to provide a guideline for researchers who have an interest in geometric innovations of passive label-free microfluidics.

A millisecond passive micromixer with low flow rate, low sample consumption and easy fabrication

Fast mixing of small volumes of solutions in microfluidic devices is essential for an accurate control and observation of the dynamics of a reaction in biological or chemical studies. It is often, however, a challenging task, as the Reynolds number (Re) in microscopic devices is typically < 100. In this report, we detail a novel mixer based on the “staggered herring bone” (SHB) pattern and “split-recombination” strategies with an optimized geometry, the periodic rotation of the flow structure can be controlled and recombined in a way that the vortices and phase shifts of the flow induce intertwined lamellar structures, thus increasing the contact surface and enhancing mixing. The optimization improves the mixing while using a low flow rate, hence a small volume for mixing and moderate pressure drops. The performances of the patterns were first simulated using COMSOL Multiphysics under different operating conditions. The simulation indicates that at very low flow rate (1–12 µL·min⁻¹) and Re (3.3–40), as well as a very small working volume (~ 3 nL), a very good mixing (~ 98%) can be achieved in the ms time range (4.5–78 ms). The most promising design was then visualized experimentally, showing results that are consistent with the outcomes of the simulations. Importantly, the devices were fabricated using a classical soft-lithography method, as opposed to additive manufacturing often used to generate complex mixing structures. This new device minimizes the sample consumption and could therefore be applied for studies using precious samples.

3D printed self-supporting elastomeric structures for multifunctional microfluidics

Microfluidic devices fabricated via soft lithography have demonstrated compelling applications such as lab-on-a-chip diagnostics, DNA microarrays, and cell-based assays. These technologies could be further developed by directly integrating microfluidics with electronic sensors and curvilinear substrates as well as improved automation for higher throughput. Current additive manufacturing methods, such as stereolithography and multi-jet printing, tend to contaminate substrates with uncured resins or supporting materials during printing. Here, we present a printing methodology based on precisely extruding viscoelastic inks into self-supporting microchannels and chambers without requiring sacrificial materials. We demonstrate that, in the submillimeter regime, the yield strength of the as-extruded silicone ink is sufficient to prevent creep within a certain angular range. Printing toolpaths are specifically designed to realize leakage-free connections between channels and chambers, T-shaped intersections, and overlapping channels. The self-supporting microfluidic structures enable the automatable fabrication of multifunctional devices, including multimaterial mixers, microfluidic-integrated sensors, automation components, and 3D microfluidics.

Sensor-Integrated Microfluidic Approaches for Liquid Biopsies Applications in Early Detection of Cancer

Cancer represents one of the conditions with the most causes of death worldwide. Common methods for its diagnosis are based on tissue biopsies-the extraction of tissue from the primary tumor, which is used for its histological analysis. However, this technique represents a risk for the patient, along with being expensive and time-consuming and so it cannot be frequently used to follow the progress of the disease. Liquid biopsy is a new cancer diagnostic alternative, which allows the analysis of the molecular information of the solid tumors via a body fluid draw. This fluid-based diagnostic method displays relevant advantages, including its minimal invasiveness, lower risk, use as often as required, it can be analyzed with the use of microfluidic-based platforms with low consumption of reagent, and it does not require specialized personnel and expensive equipment for the diagnosis. In recent years, the integration of sensors in microfluidics lab-on-a-chip devices was performed for liquid biopsies applications, granting significant advantages in the separation and detection of circulating tumor nucleic acids (ctNAs), circulating tumor cells (CTCs) and exosomes. The improvements in isolation and detection technologies offer increasingly sensitive and selective equipment's, and the integration in microfluidic devices provides a better characterization and analysis of these biomarkers. These fully integrated systems will facilitate the generation of fully automatized platforms at low-cost for compact cancer diagnosis systems at an early stage and for the prediction and prognosis of cancer treatment through the biomarkers for personalized tumor analysis.

A Microfluidic System for Studying the Effects of Disturbed Flow on Endothelial Cells

Arterial endothelium experience physical stress associated with blood flow and play a central role in maintaining vascular integrity and homeostasis in response to hemodynamic forces. Blood flow within vessels is generally laminar and streamlined. However, abrupt changes in the vessel geometry due to branching, sharp turns or stenosis can disturb the laminar blood flow, causing secondary flows in the form of vortices. Such disturbed flow patterns activate pro-inflammatory phenotypes in endothelial cells, damaging the endothelial layer and can lead to atherosclerosis and thrombosis. Here, we report a microfluidic system with integrated ridge-shaped obstacles for generating controllable disturbed flow patterns. This system is used to study the effect of disturbed flow on the cytoskeleton remodeling and nuclear shape and size of cultured human aortic endothelial cells. Our results demonstrate that the generated disturbed flow changes the orientation angle of actin stress fibers and reduces the nuclear size while increases the nuclear circularity.