Characterization of PDMS Microchannels Using Horizontally or Vertically Formed 3D-Printed Molds by Digital Light Projection

[Image: see text] Three-dimensional (3D) printing is one of the promising technologies for the fabrication of microstructures due to its versatility, ease of fabrication, and low cost. However, the direct use of 3D-printed microstructure as a microchannel is still limited due to its surface property, biocompatibility, and transmittance. As an alternative, rapid prototyping of poly(dimethylsiloxane) (PDMS) from 3D-printed microstructures ensures both biocompatibility and efficient fabrication. We employed 3D-printed molds fabricated using horizontal and vertical arrangement methods with different slice thicknesses in a digital light projection (DLP)-based 3D printing process to replicate PDMS microchannels. The replicated PDMS structures were investigated to compare their optical transmittances and surface roughness. Interestingly, the optical transmittance of PDMS from the 3D-printed mold was significantly increased via bonding two single PDMS layers. To evaluate the applicability of the replicated PDMS devices from the 3D-printed mold, we performed droplet generation in the PDMS microchannels, comparing the same device from a conventional Si-wafer mold. This study provides a fundamental understanding of prototyping microstructures from the DLP-based 3D-printed mold.