3D printing has emerged as a promising
fabrication technique for
microfluidic devices, overcoming some of the challenges associated
with conventional soft lithography. Filament-based polymer extrusion
(popularly known as fused deposition modeling (FDM)) is one of the
most accessible 3D printing techniques available, offering a wide
range of low-cost thermoplastic polymer materials for microfluidic
device fabrication. However, low optical transparency is one of the
significant limitations of extrusion-based microfluidic devices, rendering
them unsuitable for cell culture-related biological applications.
Moreover, previously reported extrusion-based devices were largely
dependent on fluorescent dyes for cell imaging because of their poor
transparency. First, we aim to improve the optical transparency of
FDM-based microfluidic devices to enable bright-field microscopy of
cells. This is achieved using (1) transparent polymer filament materials
such as poly(ethylene terephthalate) glycol (PETg), (2) optimized
3D printing process parameters, and (3) a hybrid approach by integrating
3D printed microfluidic devices with cast poly(dimethylsiloxane) (PDMS)
blocks. We begin by optimizing four essential 3D printing process
parameters (layer height, printing speed, cooling fan speed, and extrusion
flow), affecting the overall transparency of 3D printed devices. Optimized
parameters produce exceptional optical transparency close to 80% in
3D printed PETg devices. Next, we demonstrate the potential of FDM-based
3D printing to fabricate transparent micromixing devices with complex
planar and nonplanar channel networks. Most importantly, cells cultured
on native 3D printed PETg surfaces show excellent cell attachment,
spreading, and proliferation during 3 days of culture without extracellular
matrix coating or surface treatment. Next, we introduce L929 cells
inside hybrid PETg-PDMS biomicrofluidic devices as a proof of concept.
We demonstrate that 3D printed hybrid biomicrofluidic devices promote
cell adhesion, allow bright-field microscopy, and maintain high cell
viability for 3 days. Finally, we demonstrate the applicability of
the proposed fabrication approach for developing 3D printed microfluidic
devices from other FDM-compatible transparent polymers such as polylactic
acid (PLA) and poly(methyl methacrylate) (PMMA).