3D Printing of Microfluidic Systems: New Method Enables High-Resolution Manufacturing

A research team led by Huachao Mao, assistant professor of engineering technology at Purdue University’s Polytechnic College, has developed a method for manufacturing microfluidic systems with high precision and lower costs. The technique, based on Vat Photopolymerization (VPP), enables the production of multilevel microchannel structures with depths as small as 10 micrometers and widths of 100 micrometers. This innovation could be significant for various applications in biomedicine, environmental analysis, geology, and manufacturing.

Microfluidic systems are used to analyze tiny amounts of substances quickly and efficiently. In biomedical research, they play a crucial role in cancer cell analysis and the development of point-of-care diagnostic solutions. The precision of these systems depends heavily on the accuracy of their structures, which, with conventional methods, require complex and expensive manufacturing processes. The current fabrication process involves multiple production steps and the use of highly specialized equipment in cleanroom environments.

“VPP allows for the direct fabrication of highly transparent microfluidics with a much higher resolution, allowing for channels as narrow as 100 microns,” said Mao. “An emerging method within VPP is the use of liquid crystal display (LCD) technology, which uses ultraviolet light to facilitate the photopolymer solidification process.”

A key advantage of the process is its ability to produce complex structures with precise channel geometry in a single step. This eliminates the need for extensive post-processing, significantly reducing production costs. Additionally, the technology allows for the integration of microfluidic systems into portable analytical units, which can be used for rapid on-site diagnostics.

“The traditional method to fabricate microfluidic devices is costly and time-consuming,” Mao said. “Fabrication takes several steps and requires high-end equipment and a cleanroom environment.”

The research is being conducted at Purdue University’s Additive and Intelligent Manufacturing Lab. This development highlights how additive manufacturing can enhance existing fabrication processes, particularly in fields that demand high precision and transparency in manufactured structures.