Rapid prototyping of thermoplastic microfluidic devices

Abstract

Microfluidic systems can be applied to develop unique tools for cell culture, low-cost diagnostics, and precision experimentation by leveraging microscale fluid flow. As the field has expanded and matured, there is a need for rapid prototyping that is both accessible to most research groups and can readily translate toward scalable commercial manufacturing. Here, we describe a protocol that incorporates rapid computer numerical control (CNC) milling of positive molds, casting of a negative high-durometer silicone mold, and hot embossing to produce microfluidic devices composed of virtually any thermoplastic material. The method bypasses the need for high-precision machining of the bonding surfaces by using a cast acrylic stock and only milling channels, thus expanding this protocol to any CNC platform This technique represents a versatile, high-fidelity prototyping method that enables fast turnaround of prototype devices in a standard laboratory setting, while offering scalability for commercial manufacturing.