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1. Facile micro-fabrication techniques for rapid manufacturing of gallium-based liquid metal passive frequency selective surfaces

   Mitra, A.; Babu, S.; Lee, J. (May 2021, The 5-6th Thermal and Fluids Engineering Conference)

   null (Ed.)

   This presentation reports different methods of making gallium-based liquid metal (LM) microfluidics passive frequency selective surfaces (FSS). In the first method Si wafer was dry-etched to form a mold and PDMS was replicated from the Si mold to create microfluidic channels with 5x5 array of 300μm width and 200 μm height for Jerusalem cross bars structure, surrounded by four fixed 2 x 1 x 0.2 mm structures. A PDMS lid having 1 mm diameter holes obtained from SLA 3D printed pillar array was aligned and bonded to the replicated PDMS to create sealed microfluidic channels. The bonded structure was placed with lid upwards in an open top 3D printed container measuring 64mm x 64mmarea and 25 mm height. LM was flooded into the container and loaded in Temescal e-beam evaporator at atmospheric pressure. Pressure in evaporator was dropped to 5.75 x 10-6Torr. After a vacuum period of 2 hours LM filling takes place in microfluidic structures because of positive pressure differential introduced by atmospheric pressure. In second method 70 μmthick SU8-2075 stencil consisting of a patterned 1x1 array of see-through FSS structure of above-mentioned dimensions was released from oxidized Si wafer using7:1 BOE. The SU8-2075 stencil was placed over a partially cured PDMS. After complete PDMS curing, an airbrush filled with LM operating at 36 psi with spraying time of less than 5 seconds, placed 4-5 cm over the stencil yields the patterned 1x1 FSS structure after removal of SU8-2075. 

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2. Hybrid Printing of Fully Integrated Microfluidic Devices for Biosensing

   https://doi.org/10.1002/smll.202304966  

   Du, Yipu; Reitemeier, Julius; Jiang, Qiang; Bappy, Md Omarsany; Bohn, Paul W.; Zhang, Yanliang (September 2023, Small)

   Abstract The advent of 3D printing has facilitated the rapid fabrication of microfluidic devices that are accessible and cost‐effective. However, it remains a challenge to fabricate sophisticated microfluidic devices with integrated structural and functional components due to limited material options of existing printing methods and their stringent requirement on feedstock material properties. Here, a multi‐materials multi‐scale hybrid printing method that enables seamless integration of a broad range of structural and functional materials into complex devices is reported. A fully printed and assembly‐free microfluidic biosensor with embedded fluidic channels and functionalized electrodes at sub‐100 µm spatial resolution for the amperometric sensing of lactate in sweat is demonstrated. The sensors present a sensitive response with a limit of detection of 442 nmand a linear dynamic range of 1–10 mm, which are performance characteristics relevant to physiological levels of lactate in sweat. The versatile hybrid printing method offers a new pathway toward facile fabrication of next‐generation integrated devices for broad applications in point‐of‐care health monitoring and sensing. 

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3. 3D microfluidics via cyclic olefin polymer-based in situ direct laser writing

   https://doi.org/10.1039/C9LC00542K  

   Alsharhan, Abdullah T.; Acevedo, Ruben; Warren, Roseanne; Sochol, Ryan D. (August 2019, Lab on a Chip)

   In situ direct laser writing ( is DLW) strategies that facilitate the printing of three-dimensional (3D) nanostructured components directly inside of, and fully sealed to, enclosed microchannels are uniquely suited for manufacturing geometrically complex microfluidic technologies. Recent efforts have demonstrated the benefits of using micromolding and bonding protocols for is DLW; however, the reliance on polydimethylsiloxane (PDMS) leads to limited fluidic sealing ( e.g. , operational pressures <50–75 kPa) and poor compatibility with standard organic solvent-based developers. To bypass these issues, here we explore the use of cyclic olefin polymer (COP) as an enabling microchannel material for is DLW by investigating three fundamental classes of microfluidic systems corresponding to increasing degrees of sophistication: (i) “2.5D” functionally static fluidic barriers (10–100 μm in height), which supported uncompromised structure-to-channel sealing under applied input pressures of up to 500 kPa; (ii) 3D static interwoven microvessel-inspired structures (inner diameters < 10 μm) that exhibited effective isolation of distinct fluorescently labelled microfluidic flow streams; and (iii) 3D dynamically actuated microfluidic transistors, which comprised bellowed sealing elements (wall thickness = 500 nm) that could be actively deformed via an applied gate pressure to fully obstruct source-to-drain fluid flow. In combination, these results suggest that COP-based is DLW offers a promising pathway to wide-ranging fluidic applications that demand significant architectural versatility at submicron scales with invariable sealing integrity, such as for biomimetic organ-on-a-chip systems and integrated microfluidic circuits. 

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4. Programmed Internal Reconfigurations in a 3D‐Printed Mechanical Metamaterial Enable Fluidic Control for a Vertically Stacked Valve Array

   https://doi.org/10.1002/adfm.202315419  

   Supakar, Tinku; Space, David; Mejia, Sophy; Tan, Rou_Yu; Alston, Jeffrey_R; Josephs, Eric_A (April 2024, Advanced Functional Materials)

   Abstract Microfluidic valves play a key role within microfluidic systems by regulating fluid flow through distinct microchannels, enabling many advanced applications in medical diagnostics, lab‐on‐chips, and laboratory automation. While microfluidic systems are often limited to planar structures, 3D printing enables new capabilities to generate complex designs for fluidic circuits with higher densities and integrated components. However, the control of fluids within 3D structures presents several difficulties, making it challenging to scale effectively and many fluidic devices are still often restricted to quasi‐planar structures. Incorporating mechanical metamaterials that exhibit spatially adjustable mechanical properties into microfluidic systems provides an opportunity to address these challenges. Here, systematic computational and experimental characterization of a modified re‐entrant honeycomb structure are performed to generate a modular metamaterial for an active device that allows us to directly regulate flow through integrated, multiplexed fluidic channels “one‐at‐a‐time,” in a manner that is highly scalable. A design algorithm is presented, so that this architecture can be extended to arbitrary geometries, and it is expected that by incorporation of mechanical metamaterial designs into 3D printed fluidic systems, which themselves are readily expandable to any complex geometries, will enable new biotechnological and biomedical applications of 3D printed devices. 

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5. Toward Reducing Casting Defects via 3D Risers via 3D Sand-Printing: A Simulation Study

   https://doi.org/10.1007/s40962-024-01353-1  

   Shuvo, Md_Moinuddin; King, Philip; Voigt, Robert; Manogharan, Guha (May 2024, International Journal of Metalcasting)

   Abstract The 3D sand printing (3DSP) process is a binder jetting class of additive manufacturing process that can incorporate complex 3D mold designs and consolidate cores with intricate features that were previously inaccessible. Prior studies in 3DSP mold design have been shown to improve pouring and filling conditions for sand casting. However, the opportunity to improve casting quality by exploring 3D riser designs during the solidification stage has not yet been explored. In this research, three novel 3D riser geometries—ellipsoid, spherical, and a fusion riser (combination of cylindrical and ellipsoid riser) were investigated. The results were compared to the benchmark cylindrical risers to assess casting performance (e.g., reduction in shrinkage porosity, increase in solidification time). Computational solidification simulations have been presented to evaluate the characteristics of the novel risers for three different metal alloys- nickel aluminum bronze (NAB), low-carbon steel A216 (WCB), and aluminum alloy (A319) alloy. From the results of this research, spherical risers were found to provide 45% yield improvement of for the three alloys studied. In addition, the riser neck diameter using a spherical riser experienced up to 77% reduction when compared to the recommended dimensions from previous literature. Finally, one of the spherical riser designs provided 18% improvement in terms of riser-pipe safety height over the benchmark design. Findings from this research will help metalcasting industries to optimize their riser designs for complex casting geometries by implementing 3D riser geometries (via 3DSP) into traditional mold making for yield improvement and defect-free castings. 

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