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5-Axis CNC micro-milling machine for three-dimensional microfluidics.

Mitchell J C Modarelli1, Devin M Kot-Thompson1, Kazunori Hoshino1

  • 1Department of Biomedical Engineering, University of Connecticut, 260 Glenbrook Rd, Storrs, CT 06269 USA. mitchell.modarelli@uconn.edu.

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Summary
This summary is machine-generated.

Researchers can now fabricate complex 3D microfluidics affordably using a new 5-axis CNC micro-milling machine. This system offers high resolution, geometric versatility, and broad material compatibility for laboratory-based prototyping.

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Area of Science:

  • Microfluidics
  • Mechanical Engineering
  • Materials Science

Background:

  • Traditional SU-8 patterning for microfluidics is limited to 2D and requires specialized photolithography equipment.
  • 3D printing offers convenience but is restricted by material choices and resolution limitations.
  • Existing 5-axis CNC micro-milling machines are not optimized for accessible, small-batch microfluidic prototyping in research labs.

Purpose of the Study:

  • To develop an affordable, accessible 5-axis CNC micro-milling machine tailored for prototyping 3D microfluidic channels in research settings.
  • To demonstrate the machine's capability for high-resolution, high-aspect-ratio, and geometrically complex microfluidic structures.
  • To showcase the fabrication of microfluidic devices from diverse materials, including metals and polymers.

Main Methods:

  • Assembly of a 5-axis CNC micro-milling machine using commercially available and custom parts.
  • Integration with computer-aided design (CAD) and computer-aided manufacturing (CAM) software for automated operation.
  • Testing of tool compatibility and milling parameters for various materials, including metals (aluminum, brass, stainless steel, titanium alloys) and polymers (PDMS).

Main Results:

  • The developed 5-axis CNC system achieves sub-micrometer bidirectional repeatability (≤0.23 μm) and fabricates features smaller than 20 μm.
  • Demonstrated milling of a 18.1 μm wide brass wall with an aspect ratio of approximately 50:1.
  • Successfully fabricated molds for polydimethylsiloxane (PDMS) microfluidic channels with complex geometries, including channels on 90° and rounded edges.

Conclusions:

  • The new 5-axis CNC micro-milling machine provides a versatile, user-friendly benchtop solution for 3D microfluidic prototyping.
  • It enables high resolution, geometric complexity, and broad material compatibility, overcoming limitations of existing methods.
  • This accessible system empowers researchers to advance microfluidic device development in laboratory environments.