Abstract

Pushing Boundaries: High Resolution 3D Printing for Microfluidics

Gregory Nordin, Professor, Brigham Young University

Interest in 3D printing for microfluidic device fabrication is high, but routinely achieving sub-100 µm features remains a challenge. This is because microfluidic devices primarily consist of negative space features, which require different considerations compared to positive space features common in other 3D printing applications. To address this, we have developed our own stereolithographic 3D printers and materials tailored to these requirements to explore what is possible with 3D printing for high resolution microfluidics. Our approach can create channels as small as 2 µm x 2 µm. We have also developed active elements, such as valves and pumps, with the smallest valves having an active area of just 15 µm x 15 µm. With these capabilities, we have demonstrated highly integrated 3D printed microfluidic components, such as a 10-stage 2-fold serial dilutor within a 2.2 mm x 1.1 mm footprint. Additionally, we have created a fast (~1 ms) and compact (<1 mm^3) 3D printed mixer using a new multi-resolution 3D printing method. These advancements position 3D printing as an attractive alternative to costly cleanroom fabrication processes. They offer the added benefit of fast (~5-15 minute), parallel fabrication of multiple devices in a single print run due to their small size, facilitating a path to mass manufacturing.