Features of Vat-Photopolymerized Masters for Microfluidic Device Manufacturing

Abstract

The growing interest in advancing microfluidic devices for manipulating fluids within micrometer-scale channels has prompted a shift in manufacturing practices, moving from single-component production to medium-size batches. This transition arises due to the impracticality of lab-scale manufacturing methods in accommodating the increased demand. This experimental study focuses on the design of master benchmarks 1–5, taking into consideration critical parameters such as rib width, height, and the relative width-to-height ratio. Notably, benchmarks 4 and 5 featured ribs that were strategically connected to the inlet, outlet, and reaction chamber of the master, enhancing their utility for subsequent replica production. Vat photopolymerization was employed for the fabrication of benchmarks 1–5, while replicas of benchmarks 4 and 5 were generated through polydimethylsiloxane casting. Dimensional investigations of the ribs and channels in both the master benchmarks and replicas were conducted using an optical technique validated through readability analysis based on the Michelson global contrast index. The primary goal was to evaluate the potential applicability of vat photopolymerization technology for efficiently producing microfluidic devices through a streamlined production process. Results indicate that the combination of vat photopolymerization followed by replication is well suited for achieving a minimum rib size of 25 µm in width and an aspect ratio of 1:12 for the master benchmark.

An Integrated Approach to Control the Penetration Depth of 3D-Printed Hollow Microneedles

“…SLA has an ink-dependent resolution, making it possible to create complex designs on the micron scale and emerging as a prominent CAD-CAM bio-fabrication method. Specifically, inverted SLA is used because of its ability to produce high-quality designs while having a smaller footprint and lower cost [26,27]. The flexibility of adding new design features printed using recently formulated biocompatible and sterilizable photoresins has increased the biomedical applications of this biofabrication method.…”

“…The flexibility of adding new design features printed using recently formulated biocompatible and sterilizable photoresins has increased the biomedical applications of this biofabrication method. Stereolithography is considered an ideal technology for microfluidic device fabrication because of its high printing resolution and flexible design, enabling accelerated process development [27]. Additionally, stereolithography may be used to facilitate the development of personalized drug delivery systems as an alternative to address and treat infectious disease [20], emphasizing the relevance and benefit of 3D printing in biomedical research.…”