3D Printed Microfluidic Features Using Dose Control in X, Y, and Z Dimensions

Interest has grown in recent years to leverage the possibilities offered by three-dimensional (3D) printing, such as rapid iterative changes; the ability to more fully use 3D device volume; and ease of fabrication, especially as it relates to the creation of complex microfluidic devices. A major shortcoming of most commercially available 3D printers is that their resolution is not sufficient to produce features that are truly microfluidic (<100 × 100 μm(2)). Here, we test a custom 3D printer for making ~30 μm scale positive and negative surface features, as well as positive and negative features within internal voids (i.e., microfluidic channels). We found that optical dosage control is essential for creating the smallest microfluidic features (~30 µm wide for ridges, ~20 µm wide for trenches), and that this resolution was achieved for a number of different exposure approaches. Additionally, we printed various microfluidic particle traps, showed capture of 25 µm diameter polymer beads, and iteratively improved the trap design. The rapid feedback allowed by 3D printing, as well as the ability to carefully control optical exposure conditions, should lead to new innovations in the types and sizes of devices that can be created for microfluidics.