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High Throughput Microfluidic Rapid and Low Cost Prototyping Packaging Methods
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Advancing Modular Microfluidics: Stereolithographic 3D Printing of Reconfigurable Connectors for Bioanalytical

Hong-Wei Zhang1,2, Clara Tamura3, Alireza Ahmadianyazdi2

  • 1Department of Biomedical Engineering, National Cheng Kung University, Tainan, Taiwan.

International Journal of Bioprinting
|January 12, 2026
PubMed
Summary

Stereolithographic 3D printing enables modular microfluidic connectors for flexible, reconfigurable platforms. This advancement offers adaptable solutions for material synthesis, chemical analysis, and diagnostics.

Keywords:
3D printingmodular microfluidicsstereolithography

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Biomedical Engineering

Background:

  • Traditional monolithic microfluidic devices lack modularity, requiring complete redesign for modifications.
  • This limitation hinders flexibility and reusability in microfluidic system development.

Purpose of the Study:

  • To introduce modular microfluidic connectors fabricated using stereolithographic (SL) 3D printing.
  • To evaluate different connector designs for enhanced reusability, flexibility, and sealing performance.
  • To assess the suitability of these connectors for bioanalytical applications.

Main Methods:

  • Designed and fabricated three types of modular connectors: tessellated, sponge, and solid-walled.
  • Utilized tailored photoresins, including poly(ethylene glycol) diacrylate (PEGDA) and 2-hydroxyethyl acrylate (2-HEA) blends.
  • Evaluated connector performance in a reconfigurable concentration gradient generator (CGG) and conducted cytocompatibility tests.

Main Results:

  • Tessellated connectors improved PEGDA print reusability.
  • Sponge connectors offered greater flexibility but showed potential swelling issues.
  • Solid-walled connectors demonstrated superior reliability and adaptability in the CGG.
  • PEGDA-printed devices were cytocompatible for non-incubation bioanalytical applications.

Conclusions:

  • SL 3D printing is a viable method for creating flexible and reconfigurable microfluidic platforms.
  • Modular connectors offer adaptable solutions for material synthesis, chemical analysis, and point-of-care diagnostics.
  • Further research is needed to address environmental durability challenges for broader applications.