3D Microfluidic Channels via Sacrificial Material Dissolution

Solution Overview

Problem

The existing methods for manufacturing microfluidic devices are time-consuming and require high skill, especially when fabricating 3-D channels, as they involve stacking multiple layers of 2-D channels.

Innovation Solution

A method involving configuring a length of material into a desired shape, either before or after placing it in a liquid polymer, and then dissolving it to create microfluidic channels within a solid polymer, allowing for the production of channels in two or three dimensions using solvents, with the option to embed mechanical and electronic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photolithography and stacking multiple layers of 2-D channels are used to fabricate 3-D channels, then microfluidic devices can be manufactured, but the fabrication process becomes highly time-consuming and requires a high level of skill

Engineering Contradiction:

Improvechannel geometry precisionVSAvoidfabrication time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Instead of creating channels by stacking 2-D layers or using complex photolithography, the invention inverts the approach by placing a soluble sacrificial material (salt, sugar, or starch) directly into 3-D configured forms within the cured PDMS. The channels are then formed by dissolving this sacrificial material, achieving 3-D channel fabrication without layer stacking or photolithography.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces a sacrificial intermediary material (salt, sugar, or starch) that temporarily occupies the space where channels will eventually form. This intermediary is easily configurable into 3-D shapes and can be completely removed by dissolution, leaving clean channels without requiring complex fabrication processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If photolithography and stacking multiple layers of 2-D channels are used to fabricate 3-D channels, then microfluidic devices can be manufactured, but the process requires a high level of skill

Engineering Contradiction:

Improvechannel geometry precisionVSAvoidfabrication skill requirement

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Instead of creating channels by stacking 2-D layers or using complex photolithography, the invention inverts the approach by placing a soluble sacrificial material (salt, sugar, or starch) directly into 3-D configured forms within the cured PDMS. The channels are then formed by dissolving this sacrificial material, achieving 3-D channel fabrication without layer stacking or photolithography.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention uses inexpensive, easily configurable sacrificial materials (salt, sugar, or starch) that can be shaped into 3-D forms using simple methods. These materials are disposable and are completely removed by dissolution, leaving the final channel structure without requiring skilled manual assembly or complex equipment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If multiple layers of 2-D channels are stacked together to create 3-D channels, then microfluidic devices can be manufactured, but the fabrication process becomes complex and time-consuming

Engineering Contradiction:

Improvechannel dimensionalityVSAvoidfabrication process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of creating channels by stacking 2-D layers or using complex photolithography, the invention inverts the approach by placing a soluble sacrificial material (salt, sugar, or starch) directly into 3-D configured forms within the cured PDMS. The channels are then formed by dissolving this sacrificial material, achieving 3-D channel fabrication without layer stacking or photolithography.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention transitions directly from 3-D sacrificial material configuration to 3-D channel formation, eliminating the need to stack multiple 2-D layers. This dimensional approach simplifies the fabrication process while maintaining the ability to create complex 3-D channel geometries.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This approach simplifies the fabrication of microfluidic devices, enabling the creation of complex channels and integrated components efficiently, reducing fabrication time and skill requirements while allowing for the production of functional microfluidic devices with embedded components.

Implementation Method 1

dissolving the configured length of material with a solvent to provide a microfluidic channel in the solid polymer

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

curing or setting the polymer liquid to form a solid polymer around the configured length of material

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS11052388B2Method of manufacturing a microfluidic device

Publication Date: 2021.07.06 WAGENINGEN UNIVERSITEIT

AI summary

A method of manufacturing a microfluidic device, said method comprising placing a length of material in a liquid polymer, configuring the length of material to define the path of a microfluidic channel, curing or setting the polymer liquid to form a solid polymer around the configured length of material, and dissolving the configured length of material with a solvent to provide a microfluidic channel in the solid polymer.