From Soft Lithography to 3D Printing: Current Status and Future of Microfluidic Device Fabrication

The advent of 3D printing has revolutionized the fabrication of microfluidic devices, offering a compelling alternative to traditional soft lithography techniques. This review explores the potential of 3D printing, particularly photopolymerization techniques, fused deposition modeling, and material jetting, in advancing microfluidics. We analyze the advantages of 3D printing in terms of cost efficiency, geometric complexity, and material versatility while addressing key challenges such as material transparency and biocompatibility, which have represented the limiting factors for its widespread adoption. Recent developments in printing technologies and materials are highlighted, underscoring the progress in overcoming these barriers. Finally, we discuss future trends and opportunities, including advancements in printing resolution and speed, the development of new printable materials, process standardization, and the emergence of bioprinting for organ-on-a-chip applications. Sustainability and regulatory frameworks are also considered critical aspects shaping the future of 3D-printed microfluidics. By bridging the gap between traditional and emerging fabrication techniques, this review aims to illuminate the transformative potential of 3D printing in microfluidic device manufacturing.