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Castable 3D monolithic microfluidic devices
Bram Servais1,2, David R Nisbet1,2,3,4, David J Collins1,2
1Department of Biomedical Engineering, Faculty of Engineering and Information Technology, The University of Melbourne, Melbourne, Victoria, 3010 Australia. david.nisbet@unimelb.edu.au.
Lab on a Chip
|July 24, 2026
Summary
We developed a novel 3D microfabrication method using 3D printed molds and PDMS casting for scalable, low-cost 3D microfluidic devices with complex internal structures. This approach overcomes limitations of traditional methods for applications like organ-on-chip technology.
Area of Science:
- Biotechnology
- Materials Science
- Mechanical Engineering
Background:
- Traditional microfluidic fabrication methods like soft lithography and injection molding have limitations in creating complex 3D structures, hindering commercialization, especially for 3D applications.
- Soft lithography offers high resolution and biocompatibility but is limited by planar geometries and complex workflows.
- Injection molding allows scalability but lacks flexibility and involves high initial costs.
Purpose of the Study:
- To present an innovative hybrid microfabrication methodology for creating monolithic 3D microfluidic devices.
- To enable rapid, repeatable, and low-cost fabrication of complex 3D microfluidic devices with design freedom.
- To overcome the limitations of existing methods for translating 3D microfluidics into commercial products.
Main Methods:
- A hybrid microfabrication approach combining stereolithographic 3D printed molds, flexible wire templating, and polydimethylsiloxane (PDMS) casting.
- Utilizing injection molding design principles for scalable and repeatable manufacturing of microfluidic devices.
- Creating monolithic 3D microfluidic devices with embedded internal channels, variable-height membranes, and curved geometries.
Main Results:
- Successfully fabricated monolithic 3D microfluidic devices with embedded channels, variable-height membranes, and curved geometries.
- Validated the methodology with diverse devices including flexible membranes, flow distributors, and high-aspect-ratio bioreactors with integrated electrodes.
- Demonstrated that the resulting devices are leak-proof, reusable, and compatible with standard cell culture systems.
Conclusions:
- The developed hybrid microfabrication methodology offers a scalable, low-cost solution for producing complex 3D microfluidic devices.
- This approach retains the benefits of PDMS while providing significant 3D design freedom for both internal and external features.
- The methodology is well-suited for emerging applications such as organ-on-chip, bioprinting, diagnostics, and soft robotics.
