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Updated: Feb 2, 2026

Three-dimensional Printing of Thermoplastic Materials to Create Automated Syringe Pumps with Feedback Control for Microfluidic Applications
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3D Printed Microfluidic Features Using Dose Control in X, Y, and Z Dimensions.

Michael J Beauchamp1, Hua Gong2, Adam T Woolley3

  • 1Department of Chemistry and Biochemistry, Brigham Young University, Provo, UT 84602, USA. mikejbeau@byu.edu.

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|November 15, 2018
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Summary

This study demonstrates a custom three-dimensional (3D) printer capable of creating microfluidic devices with features as small as 30 micrometers. Precise optical dosage control is key to achieving this high resolution for microfluidic applications.

Keywords:
3D printingmicrofluidicsparticle trapsstereolithography

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Area of Science:

  • Microfluidics
  • Additive Manufacturing
  • Biotechnology

Background:

  • Three-dimensional (3D) printing offers advantages for fabricating complex microfluidic devices.
  • Commercial 3D printers often lack the resolution required for true microfluidic applications (<100 × 100 μm²).

Purpose of the Study:

  • To evaluate a custom 3D printer for fabricating microfluidic devices with sub-100 micrometer features.
  • To assess the impact of optical dosage control on achieving high-resolution microfluidic features.
  • To demonstrate the iterative design and fabrication of microfluidic particle traps.

Main Methods:

  • Utilized a custom 3D printer to create positive and negative surface features and internal microfluidic channels.
  • Investigated various optical exposure approaches and their effect on feature resolution.
  • Designed, printed, and tested microfluidic particle traps for capturing 25 μm polymer beads.

Main Results:

  • Achieved ~30 μm scale surface features and microfluidic channels.
  • Demonstrated that optical dosage control is crucial for creating features as small as ~30 μm (ridges) and ~20 μm (trenches).
  • Successfully captured 25 μm polymer beads using the fabricated microfluidic particle traps, with iterative design improvements.

Conclusions:

  • Custom 3D printing with precise optical dosage control enables the fabrication of high-resolution microfluidic devices.
  • Rapid prototyping and controlled exposure are vital for advancing microfluidic device design and innovation.
  • This technology opens possibilities for creating novel microfluidic devices with intricate and small-scale features.