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Automated Flushing System for Post-Processing in Microfluidic Device Fabrication.

Sebastian Zapata1, Brady Goenner2, Dallin S Miner1

  • 1Electrical and Computer Engineering Department, Brigham Young University, Provo, UT 84602, USA.

Micromachines
|May 27, 2026
PubMed
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Automating the cleaning of 3D-printed microfluidic devices using Digital Light Processing Stereolithography (DLP-SLA) is now possible with a novel chip-to-chip (C2C) system. This automated flushing platform enhances reliability and simplifies the fabrication of complex microfluidic devices.

Area of Science:

  • Microfluidics
  • 3D Printing
  • Biotechnology

Background:

  • Post-processing of microfluidic devices fabricated with Digital Light Processing Stereolithography (DLP-SLA) is a significant challenge.
  • Manual flushing methods are inefficient, inconsistent, and risk damaging delicate microfluidic components like valves and pumps.
  • Increasing device complexity and port count exacerbate these post-processing difficulties.

Purpose of the Study:

  • To develop the first fully automated flushing system for DLP-SLA 3D-printed microfluidic devices.
  • To address the limitations of manual post-processing by introducing a reliable and scalable solution.
  • To improve the fabrication workflow for complex microfluidic devices.

Main Methods:

  • Implementation of a standardized chip-to-chip (C2C) interconnect architecture.
Keywords:
DLP-SLA 3D printingautomated post-processingchip-to-chip interconnectfluidic circuit modelmicrofluidic valvesmicrofluidicspneumatic control systemresin flushing

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  • Development of an electronically controlled pneumatic routing platform with pressure controllers, sensors, and rotary valves.
  • Creation and experimental validation of a fluidic-circuit model to predict pressure drops across device structures.

    • Main Results:

    • Demonstration of robust and repeatable flushing of passive and active microfluidic elements, including channels, valves, and pumps.
    • Successful application of the system to complex devices such as mixers and concentration-gradient generators.
    • Significant improvement in valve membrane survival rates and elimination of manual handling during post-processing.

    Conclusions:

    • The developed automated flushing system provides a scalable foundation for post-processing 3D-printed microfluidics.
    • This technology significantly enhances the practicality of DLP-SLA for fabricating complex, multi-layered microfluidic devices.
    • The system offers improved efficiency, reliability, and component survival in microfluidic device fabrication.