Embedded template-assisted fabrication of complex microchannels in PDMS and design of a microfluidic adhesive

In this paper, we describe a novel method for fabricating 2-D and 3-D microchannel patterns in a flexible platform of cross-linked poly(dimethylsiloxane) (PDMS). Here, a slender nylon thread formed into different 2-D and 3-D shapes is used as a template that is embedded inside a block of cross-linked PDMS. The cross-linked network is then allowed to swell in a suitable solvent that swells the network selectively but leaves the nylon thread unaltered. The thread is then gently removed from the swollen network leaving behind a microchannel. Channels of a variety of topologically complex orientations like knots, helices, super-helices, and channels of a variety of cross-sections can be generated using this simple method. Finally, we have presented an application by generating inside layers of adhesive in these microchannels, which are observed to enhance the adhesion strength significantly.