The present contribution reports on a study aiming to find the most suitable rubbing method for filling arrays of separated and interconnected micromachined pockets with individual microspheres on rigid, uncoated silicon substrates without breaking the particles or damaging the substrate. The explored dry rubbing methods generally yielded unsatisfactory results, marked by very large percentages of empty pockets and misplaced particles. On the other hand, the combination of wet rubbing with a patterned rubbing tool provided excellent results (typically <1% of empty pockets and <5% of misplaced particles). The wet method also did not leave any damage marks on the silicon substrate or the particles. When the pockets were aligned in linear grooves, markedly the best results were obtained when the ridge pattern of the rubbing tool was moved under a 45° angle with respect to the direction of the grooves. The method was tested for both silica and polystyrene particles. The proposed assembly method can be used in the production of medical devices, antireflective coatings, and microfluidic devices with applications in chemical analysis and/or catalysis.

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The efficiency of liquid chromatography separations could be strongly improved by changing the current packed bed columns by a bundle of parallel capillary tubes. In practice, however, the polydispersity effect, which emanates from the inevitable small differences in capillary diameter, completely ruins this potential. The concept of diffusional bridging, introducing a diffusive cross talk between adjacent capillaries, has recently been proposed to resolve this. The present contribution provides the first experimental proof for this concept and quantitatively validates its underlying theory. This has been accomplished by measuring the dispersion of a fluorescent tracer in 8 different microfluidic channels with different degrees of polydispersity and diffusional bridging. The observed degree of dispersion reduction agrees very well with the theoretical predictions, hence opening the road to the use of this theory to design a new family of chromatographic beds, potentially offering unprecedented performance.