Desktop aligner for fabrication of multilayer microfluidic devices

Area of Science:

• Microfluidics
• Materials Science
• Biotechnology

Background:

• Multilayer assembly is key for complex polydimethylsiloxane (PDMS) microfluidic devices.
• Accurate alignment of PDMS layers is crucial for device yield and quality.
• Existing alignment methods may lack precision or versatility for diverse applications.

Purpose of the Study:

• To develop and validate a custom desktop aligner for precise local and global alignment of PDMS layers.
• To demonstrate the aligner's capability in fabricating complex, integrated multilayer microfluidic devices.
• To provide microfluidic researchers with a cost-effective and portable alignment solution.

Main Methods:

• Designed a desktop aligner incorporating two digital microscopes for broad-range PDMS layer alignment.
• Evaluated local and global alignment accuracy, achieving approximately 20 μm cm(-1).
• Applied the aligner to fabricate integrated multilayer devices, including organs-on-chips and devices with vertical passages.

Main Results:

• The custom aligner enables accurate alignment of PDMS layers up to 4 inches in diameter.
• Achieved high alignment accuracy suitable for complex microfluidic device fabrication.
• Demonstrated successful integration of functional layers in organs-on-chips and vertical passage devices.

Conclusions:

• The developed desktop aligner offers a convenient, accurate, and portable solution for multilayer PDMS microfluidic device fabrication.
• This tool enhances the yield and quality of complex microfluidic devices.
• It is a valuable resource for microfluidic researchers requiring precise layer alignment.