Rapid prototyping of high-resolution large format microfluidic device through maskless image guided in-situ photopolymerization

Microfluidic devices have found extensive applications in mechanical, bio- medical, chemical, and materials research. However, the high initial cost, low resolution, inferior feature fidelity, poor repeatability, rough surface finish, and long turn-around time of traditional prototyping methods limit their wider adoption. In this study, a strategic approach to a deterministic fabrication process based on in-situ image analysis and intermittent flow control called image-guided in-situ maskless lithography (IGIs-ML), has been proposed to overcome these challenges. By using dynamic image analysis and integrated flow control, IGIs-ML provides superior repeatability and fidelity of densely packed features across a large area and multiple devices. This general and robust approach enables the fabrication of a wide variety of microfluidic devices and resolves critical proximity effect and size limitations in rapid prototyping. The affordability and reliability of IGIs-ML make it a powerful tool for exploring the design space beyond the capabilities of traditional rapid prototyping.

@article{Paul23,
author = {Ratul Paul, Yuwen Zhao, Declan Coster, Xiaochen Qin, Khayrul Islam, Yue Wu, Yaling Liu},
year = {2023},
title = {Rapid prototyping of high-resolution large format microfluidic device through maskless image guided in-situ photopolymerization},
journal = {Nature Communications},
volume = {14},
number = {1},
pages = {4520},
doi = {10.1038/s41467-023-40119-x},
url = {https://www.nature.com/articles/s41467-023-40119-x}}