Microfluidic devices have transformed numerous fields, including chromatography and DNA sequencing, due to their ability to manipulate fluids at the microscale. These devices are pivotal in creating compact, efficient systems for applications ranging from point-of-care diagnostic tests to high-throughput drug screening. Devices are often made by photolithography, which allows for high resolution but leads to significant challenges like integrated nozzles or intricate routing, since the channel pattern must be two-dimensional. 3D printing has emerged as a potential approach to overcome these limitations, but its current resolution of 50µm holds back the fabrication of features at the scale required for precise microfluidic operations. Therefore, our group has proposed that a hybrid device that combines a 3D-printed part and a microfabricated part would offer favorable results for processing single cells at a high throughput. We fabricated a device that consists of a complex microfluidic channel system with an onboard 3D-printed reservoir and two external nozzles. Preliminary parts were modeled on OnShape’s CAD software, printed through Formlabs with Tough1500 resin, then iteratively optimized to meet the required volume capacity and nozzle dimensions. Separately, photolithographically-patterned microfluidic chips were fabricated from transparent epoxy - to allow for visibility of cells within the device. Finally, the micropatterned part was bonded to the aforementioned printed parts and finalized devices were tested against a predetermined quality control checklist. Altogether, these devices demonstrate successful integration of high-resolution channels with 3D-printed routing and nozzle systems. Our approach resolves the limitations of planar fabrication and enhances the functionality of the device by enabling multi-layer and complex geometries. This innovation is significant because it paves the way for complex microfluidic devices with enhanced capabilities, fostering advancements in fields such as personalized medicine and synthetic biology. Furthermore, it underscores the importance of combining technologies to meet the evolving demands of microfluidics.
Hybrid Microfluidic Devices Using Photolithography and 3D printing
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Student Abstract Submission