3D-Printed Microfluidic Chips for Viable Biological Samples
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Solution Overview
Problem
Existing microfluidic devices face challenges in maintaining biological samples in viable conditions due to insufficient biocompatibility, limited optical transparency, and difficulty in designing complex flow conditions, which affects drug screening and personalized therapy applications.
Innovation Solution
A method for manufacturing microfluidic devices using biocompatible UV-curable resins printed on hydrophilic substrates, allowing for customizable channel designs and multiple-use access through a capping mechanism, ensuring adhesion and longevity of biological samples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PDMS is used as the substrate material, then biocompatibility and optical transparency are improved, but device complexity and manufacturing difficulty increase due to the need for complex fabrication processes
Solution Approach 1:
The patent replaces complex mechanical fabrication processes (laser writing, multiple printing steps, UV curing) with a simplified extrusion-based manufacturing system. The microfluidic device is fabricated by directly extruding photopolymerizable material through a nozzle, eliminating the need for complex PDMS fabrication processes while maintaining biocompatibility and optical transparency.
Solution Approach 2:
The patent changes the material parameter from traditional PDMS to a photopolymerizable extrudable material. This material can be extruded through a nozzle and cured in-situ, allowing direct formation of complex microfluidic structures without requiring complex fabrication processes, thus reducing device complexity while maintaining reliability.
2Ease of manufacture
If conventional printing methods are used, then manufacturing simplicity is improved, but manufacturing precision deteriorates due to inability to form complex microfluidic structures
Solution Approach 1:
The patent replaces conventional printing methods with a controlled extrusion system that deposits material layer-by-layer through a nozzle. This method combines the simplicity of printing processes with the precision needed for microfluidic structures, as the extrusion process can be precisely controlled to form accurate channel geometries.
Solution Approach 2:
The patent utilizes photopolymerization as a phase transition mechanism. The extruded photopolymerizable material is cured in-situ upon contact with UV light or ambient atmosphere, transforming from a liquid/extrudable state to a solid cured state. This allows precise formation of complex microfluidic structures during the printing process itself, achieving both ease of manufacture and manufacturing precision.
3Ease of operation
If single-use devices are manufactured, then ease of operation is improved, but loss of substance increases due to inability to reuse
Solution Approach 1:
The patent incorporates a movable cap assembly that can be opened and closed to access the biological sample chamber. This dynamic structure allows the device to transition between sealed and accessible states, enabling multiple uses while maintaining ease of operation for sample access. The cap can be removed or opened as needed and closed to seal the chamber, preventing material waste.
Solution Approach 2:
The patent divides the device into separable components, including a removable cap assembly and a main body. This segmentation allows the cap to be independently accessed or removed without affecting the main device structure, facilitating easy operation for sample access while enabling the device to be reused by simply reclosing the cap.
4Adaptability or versatility
If complex flow conditions are designed, then adaptability is improved, but device complexity increases due to difficulty in designing and manufacturing
Solution Approach 1:
The patent replaces complex mechanical design and manufacturing processes with a computational approach. The microfluidic channel network is designed using computer-aided design (CAD) software, allowing complex flow conditions to be simulated and optimized before fabrication. This enables creation of versatile devices with controlled flow patterns without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent utilizes the extrudability and photopolymerizability of the material to form complex three-dimensional channel networks that would be difficult to manufacture using traditional methods. By controlling the extrusion process and subsequent curing, the device can incorporate varied channel geometries, heights, and configurations to achieve different flow conditions while maintaining manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables maintaining biological samples in viable conditions for extended periods, facilitating drug screening and personalized therapy by providing flexible design, optical transparency, and multiple-use access, while overcoming the limitations of traditional PDMS devices.
Implementation Method 1
printing a first layer of a biocompatible UV-curable polymeric resin onto a substrate having a hydrophilic surface; applying UV radiation to cure said first layer
Data Source
AI summary
The disclosure provides microfluidic chips and systems for maintaining viability of biological sample, and methods for their production by direct 3-D printing of biocompatible UV-curable polymeric resins.