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World-to-chip (macro-to-micro) interface continues to be one of the most complicated, ineffective, and unreliable components in the development of emerging lab-on-a-chip systems involving integrated microfluidic operations. A number of irreversible (e.g., adhesive gluing) and reversible techniques (e.g., press fitting) have attempted to provide dedicated fluidic passage from standard tubing to miniature on-chip devices, none of which completely addresses the above concerns. In this paper, we present standardized adhesive-free microfluidic adaptors, referred to as Fit-to-Flow (F2F) Interconnects, to achieve reliable hermetic seal, high-density tube packing, self-aligned plug-in, reworkable connectivity, straightforward scalability and expandability, and applicability to broad lab-on-a-chip platforms; analogous to the modular plug-and-play USB architecture employed in modern electronics. Specifically, two distinct physical packaging mechanisms are applied, with one utilizing induced tensile stress in elastomeric socket to establish reversible seal and the other using negative pressure to provide on demand vacuum shield, both of which can be adapted to a variety of experimental configurations. The non-leaking performance (up to 336 kPa) along with high tube-packing density (of 1 tube/mm2) and accurate self-guided alignment (of 10 μm) have been characterized. In addition, a 3D microfluidic mixer and a 6-level chemical gradient generator paired with the corresponding F2F Interconnects have been devised to illustrate the applicability of the universal fluidic connections to classic lab-on-a-chip operations. [ABSTRACT FROM AUTHOR]

As an emerging alternative to the conventional counterpart, surface microfluidics incorporates both intrinsic resistive solid-liquid and elastic frictionless gas-liquid interfaces, leading to unique flow-pressure characteristics. Furthermore, the open-surface microfluidic platforms can be fabricated on a monolithic substrate with high wettability contrast by the previously reported one-step lithographic process of a photosensitive superhydrophobic nanocomposite material, which permits flexible fluidic operations and direct surface modifications. In the paper, we first present three-dimensional microfluidic manipulations utilizing the unconventional gas-liquid interfaces of surface microfluidics, outlined by the micropatterned wetting boundaries (also known as the triple lines). In contrast to the primary linear (resistive) nature of the conventional closed-channel microfluidics, the distinct elastic interface of surface microfluidics enables remarkable three-dimensional (deformable) and time-dependent (capacitive) operations of the flow. Specifically, spatiotemporal dependence of microflow patterns on the planar fluidic surfaces has been theoretically analyzed and experimentally characterized. Utilizing the unconventional interface-enabled flow-pressure relationship, novel surface fluidic operations, including microflow regulation and flow-controlled switching, have been demonstrated and fully investigated. Furthermore, three-dimensional surface microfluidic networks together with analog-to-digital stereo-flow activations have been established, in which miniature capillary bridges form fluidic connections between two independent surface microfluidic circuits. [ABSTRACT FROM AUTHOR]

Droplet-based transport phenomena driven by surface tension have been explored as an automated pumping source for a number of chemical and biological applications. In this paper, we present a comprehensive theoretical and experimental investigation of unconventional droplet-based motions on a superhydrophobic-patterned surface microfluidic (S2M) platform. The S2M surfaces are monolithically fabricated using a facile two-step laser micromachining technique on regular polydimethylsiloxane (PDMS) chemistry. Unlike the traditional droplet-driven pumps built on an enclosed microfluidic network, the S2M network pins the liquid–solid interface of droplets to the lithographically defined wetting boundary and establishes a direct linkage between the volumetric and hydraulic measures. Moreover, diverse modes of droplet motions are theoretically determined and experimentally characterized in a bi-droplet configuration, among which several unconventional droplet-driven transport phenomena are first demonstrated. These include big-to-small droplet merging, droplet balancing, as well as bidirectional transporting, in addition to the classic small-to-big droplet transition. Furthermore, multi-stage programmable bidirectional pumping has been implemented on the S2M platform, according to the newly established droplet manipulation principle, to illustrate its potential use for automated biomicrofluidic and point-of-care diagnostic applications. [ABSTRACT FROM AUTHOR]

In this paper, we present a novel rapid-prototyping process for out-of-cleanroom microfabrication of three-dimensional multilayer microfluidic structures with a 10 µm resolution, referred to as the Direct Projection on Dry-film Photoresist (DP2). A commercially available digital projector is customized to function as a direct mask generation and photo exposure system, while easy-processing photosensitive dry films are used as the microfluidic constructs. Multilayer alignments among maskless-patterned layers are reliably achieved by using a Software Alignment technique with less than 10 µm precision, which eliminates the use of mechanical travelling stage. The bonding between different layers of dry film, simply enabled by a plasma-assisted thermal lamination, offers an easy implementation for suspended multilayer microstructures. Development of a complex microfluidic chip from computer layout can thus be accomplished within an hour in a regular chemical or biological lab environment using this approach. [ABSTRACT FROM AUTHOR]

With the major advances in soft lithography and polymer materials, use of microfluidic devices has attracted tremendous attention recently. A simple and fast micromachining process is highly in demand to prototype such a device efficiently and economically. In this paper, we first reported an out-of-cleanroom printing-based integrated microfabrication process, referred to as the lab-on-a-print(LOP), for rapid-prototyping three-dimensional microfluidics. Using this lab-on-a-printprocess, we demonstrated the potential to accomplish an entire design-to-fabrication cycle within an hour, including about 70 µm resolution of direct-lithography patterning, well-controlled polyimide wet etching, three-dimensional pattern alignment and multilayer wax thermal-fusion packaging. A microfluidic gradient generator was prepared and tested for validation of the lab-on-a-printmicrofabrication process. [ABSTRACT FROM AUTHOR]

Packaging continues to be one of the most challenging steps in micro-nanofabrication, as many emerging techniques (e.g., soft lithography) are incompatible with the standard high-precision alignment and bonding equipment. In this paper, we present a simple-to-operate, easy-to-adapt packaging strategy, referred to as Capillary-driven Automatic Packaging (CAP), to achieve automatic packaging process, including the desired features of spontaneous alignment and bonding, wide applicability to various materials, potential scalability, and direct incorporation in the layout. Specifically, self-alignment and self-engagement of the CAP process induced by the interfacial capillary interactions between a liquid capillary bridge and the top and bottom substrates have been experimentally characterized and theoretically analyzed with scalable implications. High-precision alignment (of less than 10 µm) and outstanding bonding performance (up to 300 kPa) has been reliably obtained. In addition, a 3D microfluidic network, aligned and bonded by the CAP technique, has been devised to demonstrate the applicability of this facile yet robust packaging technique for emerging microfluidic and bioengineering applications. [ABSTRACT FROM AUTHOR]