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In-situ transfer vat photopolymerization for transparent microfluidic device fabrication

While vat photopolymerization has many advantages over soft lithography in fabricating microfluidic devices, including efficiency and shape complexity, it has difficulty achieving well-controlled micrometer-sized (smaller than 100 μm) channels in the layer building direction. The considerable light...

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Autores principales: Xu, Yang, Qi, Fangjie, Mao, Huachao, Li, Songwei, Zhu, Yizhen, Gong, Jingwen, Wang, Lu, Malmstadt, Noah, Chen, Yong
Formato: Online Artículo Texto
Lenguaje:English
Publicado: Nature Publishing Group UK 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8854570/
https://www.ncbi.nlm.nih.gov/pubmed/35177598
http://dx.doi.org/10.1038/s41467-022-28579-z
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author Xu, Yang
Qi, Fangjie
Mao, Huachao
Li, Songwei
Zhu, Yizhen
Gong, Jingwen
Wang, Lu
Malmstadt, Noah
Chen, Yong
author_facet Xu, Yang
Qi, Fangjie
Mao, Huachao
Li, Songwei
Zhu, Yizhen
Gong, Jingwen
Wang, Lu
Malmstadt, Noah
Chen, Yong
author_sort Xu, Yang
collection PubMed
description While vat photopolymerization has many advantages over soft lithography in fabricating microfluidic devices, including efficiency and shape complexity, it has difficulty achieving well-controlled micrometer-sized (smaller than 100 μm) channels in the layer building direction. The considerable light penetration depth of transparent resin leads to over-curing that inevitably cures the residual resin inside flow channels, causing clogs. In this paper, a 3D printing process — in-situ transfer vat photopolymerization is reported to solve this critical over-curing issue in fabricating microfluidic devices. We demonstrate microchannels with high Z-resolution (within 10 μm level) and high accuracy (within 2 μm level) using a general method with no requirements on liquid resins such as reduced transparency nor leads to a reduced fabrication speed. Compared with all other vat photopolymerization-based techniques specialized for microfluidic channel fabrication, our universal approach is compatible with commonly used 405 nm light sources and commercial photocurable resins. The process has been verified by multifunctional devices, including 3D serpentine microfluidic channels, microfluidic valves, and particle sorting devices. This work solves a critical barrier in 3D printing microfluidic channels using the high-speed vat photopolymerization process and broadens the material options. It also significantly advances vat photopolymerization’s use in applications requiring small gaps with high accuracy in the Z-direction.
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spelling pubmed-88545702022-03-04 In-situ transfer vat photopolymerization for transparent microfluidic device fabrication Xu, Yang Qi, Fangjie Mao, Huachao Li, Songwei Zhu, Yizhen Gong, Jingwen Wang, Lu Malmstadt, Noah Chen, Yong Nat Commun Article While vat photopolymerization has many advantages over soft lithography in fabricating microfluidic devices, including efficiency and shape complexity, it has difficulty achieving well-controlled micrometer-sized (smaller than 100 μm) channels in the layer building direction. The considerable light penetration depth of transparent resin leads to over-curing that inevitably cures the residual resin inside flow channels, causing clogs. In this paper, a 3D printing process — in-situ transfer vat photopolymerization is reported to solve this critical over-curing issue in fabricating microfluidic devices. We demonstrate microchannels with high Z-resolution (within 10 μm level) and high accuracy (within 2 μm level) using a general method with no requirements on liquid resins such as reduced transparency nor leads to a reduced fabrication speed. Compared with all other vat photopolymerization-based techniques specialized for microfluidic channel fabrication, our universal approach is compatible with commonly used 405 nm light sources and commercial photocurable resins. The process has been verified by multifunctional devices, including 3D serpentine microfluidic channels, microfluidic valves, and particle sorting devices. This work solves a critical barrier in 3D printing microfluidic channels using the high-speed vat photopolymerization process and broadens the material options. It also significantly advances vat photopolymerization’s use in applications requiring small gaps with high accuracy in the Z-direction. Nature Publishing Group UK 2022-02-17 /pmc/articles/PMC8854570/ /pubmed/35177598 http://dx.doi.org/10.1038/s41467-022-28579-z Text en © The Author(s) 2022 https://creativecommons.org/licenses/by/4.0/Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/ (https://creativecommons.org/licenses/by/4.0/) .
spellingShingle Article
Xu, Yang
Qi, Fangjie
Mao, Huachao
Li, Songwei
Zhu, Yizhen
Gong, Jingwen
Wang, Lu
Malmstadt, Noah
Chen, Yong
In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title_full In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title_fullStr In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title_full_unstemmed In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title_short In-situ transfer vat photopolymerization for transparent microfluidic device fabrication
title_sort in-situ transfer vat photopolymerization for transparent microfluidic device fabrication
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8854570/
https://www.ncbi.nlm.nih.gov/pubmed/35177598
http://dx.doi.org/10.1038/s41467-022-28579-z
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