Submicron Fluidic Channel Fabrication Beyond 3D Printer Resolution
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Solution Overview
Problem
Commercial 3D printers have a resolution of tens of µm and a stably printable resolution of only hundreds of µm, making it difficult to fabricate nanostructures such as nanofluidic diodes within fluidic channels.
Innovation Solution
A method involving creating a 3D model with micropores, adjusting print orientation to align with the layer thickness direction, and applying heat and pressure to form submicron-sized fluidic channels using a commercial 3D printer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to fabricate nanofluidic diodes, then manufacturing precision can be improved, but device complexity and ease of manufacture deteriorate due to requiring high-class cleanroom, photo aligner, wet station, and spin coater
Solution Approach 1:
The patent extracts the essential function of photolithography (pattern formation) and implements it through a simplified 3D printing process with post-processing steps, eliminating the need for cleanroom facilities, photo aligners, wet stations, and spin coaters while maintaining the ability to create precise microstructures
Solution Approach 2:
The patent changes the manufacturing parameters from traditional photolithography (wavelength, exposure time, development) to 3D printing parameters (layer thickness, print orientation, heat treatment temperature and pressure), enabling the same fabrication goal to be achieved through a different parameter space that avoids complex equipment requirements
2Ease of manufacture
If commercial 3D printers are used to print nanostructures, then ease of manufacture is improved, but manufacturing precision deteriorates due to resolution limits of tens to hundreds of µm
Solution Approach 1:
The patent exploits the third dimension (layer thickness direction) to achieve high precision that cannot be obtained in the XY plane. By orienting the minimum diameter of micropores along the Z-axis (layer thickness direction) and using thin layers (10-100 µm), the effective resolution becomes the layer thickness rather than the XY printing resolution, enabling submicron precision with commercial 3D printers
Solution Approach 2:
The patent performs preliminary actions during the 3D printing process by strategically designing micropore dimensions and orientations in the printed object, specifically creating pores with minimum diameters in the layer thickness direction. This preliminary structuring enables the subsequent heat and pressure treatment to effectively form submicron fluidic channels with controlled dimensions
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
Enables the fabrication of submicron fluidic channels with diameters less than 1 µm, overcoming the limitations of conventional 3D printer resolutions and photolithography processes.
Implementation Method 1
applying predetermined heat and pressure to the printed object
Implementation Method 2
applying predetermined heat and pressure to the printed object
Implementation Method 3
forming submicron-sized fluidic channels by bringing two points, which form a minimum diameter of pores implemented in the printed object, into close contact with each other
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
The present invention relates to a method for manufacturing a submicron fluidic channel by using a 3D printer, and a submicron fluidic channel manufactured thereby. The method for manufacturing a submicron fluidic channel comprises the steps of: (a) modeling a 3D model including micropores; (b) adjusting the output direction of the minimum diameter of the micropores to be in the layer thickness direction of a 3D printer, to print the 3D model; and (c) forming a fluidic channel of a submicron size by applying predetermined heat and pressure to the printed output, wherein step (c) is a step in which a fluidic channel is formed through tight contact of two points forming the minimum diameter of the pores implemented in the printed output.