Toolkit for integrating millimeter-sized microfluidic biomedical devices with multiple membranes and electrodes

Area of Science:

• Biomedical Engineering
• Materials Science
• Microfluidics

Background:

• Microfluidic systems are becoming more complex, requiring advanced fabrication techniques beyond traditional lithography.
• 3D printing offers geometric freedom but struggles with integrating essential components like membranes and electrodes.
• Existing methods face challenges in creating intricate, multi-component microfluidic devices.

Purpose of the Study:

• To develop a versatile toolkit for fabricating free-standing 3D microfluidic systems for biomedical devices.
• To enable the seamless integration of flow channels, electrodes, and membranes within microfluidic devices.
• To create millimeter-scale devices suitable for implantable applications.

Main Methods:

• Utilizing molding separation with 3D printed molds, laser-based processing, and component assembly for micron-resolution fabrication.
• Introducing a novel replica molding technique for direct membrane integration into elastomer-based microfluidics.
• Employing reactive ion etching to remove elastomer residues and preserve membrane functionality.

Main Results:

• Successfully fabricated membrane-elastomer microfluidic components that simplify intricate system assembly.
• Achieved millimeter-scale device dimensions, making them suitable for implantable applications.
• Demonstrated the toolkit's versatility with a millimeter-scale redox flow iontophoretic drug delivery prototype.

Conclusions:

• The developed toolkit offers a versatile approach for fabricating complex 3D microfluidic systems.
• The novel membrane integration method simplifies assembly and enables miniaturization for biomedical applications.
• The technology holds promise for advanced implantable devices, such as iontophoretic drug delivery systems.