Low-Cost Microfabrication Tool Box

Abstract

Microsystems are key enabling technologies, with applications found in almost every industrial field, including in vitro diagnostic, energy harvesting, automotive, telecommunication, drug screening, etc. Microsystems, such as microsensors and actuators, are typically made up of components below 1000 microns in size that can be manufactured at low unit cost through mass-production. Yet, their development for commercial or educational purposes has typically been limited to specialized laboratories in upper-income countries due to the initial investment costs associated with the microfabrication equipment and processes. However, recent technological advances have enabled the development of low-cost microfabrication tools. In this paper, we describe a range of low-cost approaches and equipment (below £1000), developed or adapted and implemented in our laboratories. We describe processes including photolithography, micromilling, 3D printing, xurography and screen-printing used for the microfabrication of structural and functional materials. The processes that can be used to shape a range of materials with sub-millimetre feature sizes are demonstrated here in the context of lab-on-chips, but they can be adapted for other applications. We anticipate that this paper, which will enable researchers to build a low-cost microfabrication toolbox in a wide range of settings, will spark a new interest in microsystems.

Numerical Study of Multivortex Regulation in Curved Microchannels with Ultra-Low-Aspect-Ratio

“…However, such unique channel designs often face the challenge of high microchannel production and cost increase because of the standard soft lithography and stereolithography technology [ 18 ]. Currently, compared with other approaches to producing microfluidic devices (e.g., micromachining, micromilling, hot embossing, and injection molding), the standard soft lithography and stereolithography technology is the most promising method for the routine creation of microfluidic structures [ 31 , 32 , 33 , 34 , 35 , 36 ]. Therefore, a low-aspect-ratio (AR) channel should be developed instead of a high-AR channel.…”

Cheap, versatile, and turnkey fabrication of microfluidic master molds using consumer-grade LCD stereolithography 3D printing

“…However, this process can be very expensive, and not accessible in every lab [5]. Moreover, not all applications require the finest resolutions possible, and it is more relevant in various cases to engineer cheaper microfluidic chips [6]. The focus is rather being drawn on the variety of circuits that can be engineered and processed in a short time period [7].…”

Rapid Fabrication of Superhydrophobic Virtual Walls for Microfluidic Gas Extraction and Sensing

“…Compared to laser engraving, xurography offers several advantages [28], such as flexible material choice, safer operation, and lower equipment cost. The deployment of xurography as a manufacturing tool has been validated for many types of microfluidic applications [27,[30][31][32], as has recently been reviewed [23].…”

“…A critical issue in all of those developments is often the costly and laboratory-intensive fabrication procedure, which usually requires multi-step, clean room processing. Recent efforts have been devoted to finding alternative, lithography-free approaches for chip fabrication, and procedures with controllable micropatterning, such as 3D printing [ 16 , 17 , 18 , 19 ], paper-based microchips [ 20 , 21 , 22 ] and a range of other low-cost microfabrication techniques [ 23 ]. The application of double-sided tape with channel structures (cut with a laser engraver or cutter device; also known as xurography or razor writing) has also been reported in recent years, and can ease the design, fabrication and integration of microchips [ 24 , 25 , 26 , 27 , 28 , 29 , 30 ].…”