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Multipath Projection Stereolithography for Three-Dimensional Printing Microfluidic Devices.

Zachary J Geffert1, Zheng Xiong1,2, Jenna Grutzmacher1

  • 1Department of Biomedical and Chemical Engineering, Syracuse University, 900 S Crouse Avenue, Syracuse, New York 13244, United States.

ACS Applied Materials & Interfaces
|December 3, 2024
PubMed
Summary
This summary is machine-generated.

Multipath projection stereolithography (MPS) enables printing of centimeter-sized microfluidic devices with microscale features. This new optical printing method overcomes limitations of current 3D printing for lab-on-chip applications.

Keywords:
3D printingadditive manufacturingmultiscalephotopolymerizationprecision microfluidics

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Area of Science:

  • Biomedical Engineering
  • Materials Science
  • Optical Engineering

Background:

  • Lab-on-chip devices require inch-sized constructs with microscale resolution.
  • Current 3D printing methods face challenges in balancing print resolution, design complexity, and build size for microfluidic devices.

Purpose of the Study:

  • To introduce a novel optical printer, multipath projection stereolithography (MPS), for fabricating microfluidic devices.
  • To enable the printing of centimeter-sized devices with high-resolution microscale features.

Main Methods:

  • Developed MPS with switchable optical paths (1× for ~10 μm resolution, 3× for ~30 μm resolution) for centimeter-scale (3 × 6 cm) printing.
  • Optimized resin formulations and integrated slicing software with hardware for user-friendly operation.
  • Utilized a computational model, validated experimentally, to simulate and optimize microfluidic designs.

Main Results:

  • Successfully printed centimeter-sized microfluidic devices with ~10 μm feature resolution using MPS.
  • Demonstrated the ability to embed microscale fins within low-resolution structures using the dual-mode printing capability.
  • Verified simulated mixing efficiencies for various micromixer designs, including novel 3D out-of-plane configurations.
  • Showcased broad applicability by printing multichambered chips and microfluidic devices with microtraps.

Conclusions:

  • MPS is a versatile fabrication tool for rapidly producing diverse lab-on-chip applications.
  • The technology overcomes existing trade-offs in 3D printing for microfluidics.
  • MPS facilitates the creation of complex microfluidic devices with integrated microscale features.