Moving from millifluidic to truly microfluidic sub-100-μm cross-section 3D printed devices

Area of Science:

• Engineering
• Biotechnology
• Materials Science

Background:

• Three-dimensional (3D) printing is an emerging technology with significant potential in microfluidics.
• Current 3D printed microfluidic devices are often larger than truly microfluidic scales.
• Applications include point-of-care diagnostics and lab-on-a-chip systems.

Purpose of the Study:

• To critically analyze the cross-sectional sizes of existing 3D printed microfluidic structures.
• To explore the potential of 3D printing for fabricating smaller microfluidic features.
• To provide a prognosis for advancing 3D printed microfluidics for bioanalysis.

Main Methods:

• Classification of 3D printed fluidic channels based on cross-sectional size: millifluidic (>1 mm), sub-millifluidic (0.5–1.0 mm), large microfluidic (100–500 μm), and truly microfluidic (<100 μm).
• Prognosis for creating 10–100 μm cross-section microfluidic features using custom resins and stereolithography.

Main Results:

• Existing 3D printed microfluidic devices often fall into millifluidic or large microfluidic categories.
• The study outlines a path towards achieving smaller, truly microfluidic dimensions (10–100 μm).

Conclusions:

• 3D printing offers a versatile platform for rapid prototyping and customization of microfluidic devices.
• Advancements in materials and printing techniques will enable the creation of smaller microfluidic channels.
• 3D printed microfluidic devices promise to accelerate bioanalysis research and improve assay development.