Injection molded microfluidic chips featuring integrated interconnects

An injection molding process for the fabrication of disposable plastic microfluidic chips with a cycle time of 2 min has been designed, developed, and implemented. Of the sixteen commercially available grades of cyclo-olefin copolymer (COC) that were screened for autofluorescence and transparency to ultraviolet (UV) light, Topas 8007 x 10 was identified as the most suitable for production. A robust solid metal mold insert defining the microfluidic channels was rapidly microfabricated using a process that significantly reduces the time required for electroplating. No wear of the insert was observed even after over 1000 cycles. The chips were bonded by thermal fusion using different bonding conditions. Each condition was tested and its suitability evaluated by burst pressure measurements. The COC microfluidic chips feature novel, integrated, reversible, standardized, ready-to-use interconnects that enable operation at pressures up to 15.6 MPa, the highest value reported to date. The suitability of these UV transparent, high pressure-resistant, disposable devices was demonstrated by in situ preparation of a high surface area porous polymer monolith within the channels.     

Interaction of chitosan and mucin in a biomembrane model environment

Thermoplastics have been increasingly used for fabricating microfluidic devices because of their low cost, mechanical/biocompatible attributes, and well-established manufacturing processes. However, there is sometimes a need to integrate such a device with components made from other materials such as polydimethylsiloxane (PDMS). Bonding thermoplastics with PDMS to produce hybrid devices is not straightforward. We have reported our method to modify the surface property of a cyclic olefin copolymer (COC) substrate by using corona discharge and grafting polymerization of 3-(trimethoxysilyl)propyl methacrylate; the modified surface enabled strong bonding of COC with PDMS. In this paper, we report our studies on the surface modification mechanism using attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR), X-ray photoelectron spectroscopy (XPS), atomic force microscopy (AFM) and contact angle measurement. Using this bonding method, we fabricated a three-layer (COC/PDMS/COC) hybrid device consisting of elastomer-based valve arrays. The microvalve operation was confirmed through the displacement of a dye solution in a fluidic channel when the elastomer membrane was pneumatically actuated. Valve-enabled microfluidic handling was demonstrated.     

Low temperature bonding of PMMA and COC microfluidic substrates using UV/ozone surface treatment

The use of UV/ozone surface treatments for achieving low temperature bonds between PMMA and COC microfluidic substrates is evaluated. Low temperature bond strengths, approaching those of native polymer substrates bonded above their glass transition temperatures, are demonstrated for both thermoplastics. To evaluate the effects of the UV/O(3) surface treatment on the operation of bonded microfluidic devices, the relationship between UV/O(3) exposure and polymer hydrophilicity and surface chemistry are measured. Post-treatment surface chemistry is evaluated by XPS (X-ray photoelectron spectroscopy) analysis, and the stability of the treated surfaces following solvent exposure is reported. Electroosmotic flow within fabricated microchannels with modified wall surfaces is also characterized. Overall, UV/O(3) treatment is found to enable strong low temperature bonds between thermoplastic microfluidic substrates using a simple, low cost, and high throughput fabrication technology.     

An inkjet printing soft photomask and its application on organic polymer substrates

This article presents a simple, fast and low-cost method to fabricate a flexible UV light photomask. The designed micropatterns were directly printed onto transparent hybrid composite film of biaxially oriented polypropylene coated with silica oxide (BOPP-SiO _x ) by an inkjet printer. Compared to the conventional chrome-mask, it is of advantages such as suitable for non-planar substrates, scalable for large area production, and extreme low cost. Combined with the confined photo-catalytic oxidation (CPO) reaction, the printed flexible BOPP-SiO _x photomask was successfully used to pattern the shape of wettability of organic polymer surfaces, and then polyaniline patterns were deposited on the modified substrates with strong adhesion. With the above photomasks, the polyacrylic acid graft chains were duplicated on the poly (ethylene terephthalate) (PET) and BOPP substrates by photografting polymerization. We grafted polyacrylic acid (PAA) on a non-planar plastic substrate with this soft and thin plastic photomask. Scanning electron microscopy (SEM) and optical microscopy were used to characterize the surface morphology and thickness of ink layers of the printed photomask. Optical microscopy was used to characterize the deposition polyaniline micropatterns. It was found that the desired patterns were precisely printed on the modified polymer films and were applied in modifying organic polymer substrates. The printed photomask could be exploited in the fields such as prototype microfluidics, micro-sensors, optical structures and any other kind of microstructures which does not require high durability and dimensional stability.     

Pattern generation of biological ligands on a biodegradable poly(glycolic acid) film

The micropatterns of biological ligands (biotin and RGD peptides) were generated on a flat surface of biodegradable polymer, poly(glycolic acid) (PGA). The immobilization of biological ligands onto the surface of biodegradable polymers (especially aliphatic polyesters) is usually hampered by the absence of functionalizable groups on the polymer backbone. We demonstrate herein that PGA polymer films were modified by surface hydrolysis to introduce carboxylic acid groups on the film surfaces, which were subsequently used for patterning amine-terminated ligands by microcontact printing. Fluorescence microscopy was used to verify the pattern of biotin on the surface of the PGA films after complexation with fluorescein-conjugated streptavidin. In addition, the cellular micropatterns were obtained from micropatterns of RGD peptides on the surface-hydrolyzed PGA films.     

Multilayer assembly and patterning of poly(p-phenylenevinylene)s via covalent coupling reactions

Poly(p-phenylenevinylene)s with amines and pentafluorophenyl esters on side chains were synthesized and assembled on solid substrates by sequential layer-by-layer (LBL) deposition. This approach enables the creation of robust multilayer thin films via in-situ covalent coupling reactions between successive layers. The buildup of the multilayers was followed by UV/vis absorption spectroscopy and ellipsometry. The observed complex assembly behavior suggests that both covalent and hydrogen-bonding interactions are involved in the formation of multilayer films. The organized structure and surface morphology of resultant multilayers were investigated by reflectance Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy, and atomic force microscopy. This covalent LBL method was further applied to generate conjugated polymer micropatterns using microstamped self-assembled monolayers as templates.     

Hydrophilic surface modification of cyclic olefin copolymer microfluidic chips using sequential photografting

The plastic material known as cyclic olefin copolymer (COC) is a useful substrate material for fabricating microfluidic devices due to its low cost, ease of fabrication, excellent optical properties, and resistance to many solvents. However, the hydrophobicity of native COC limits its use in bioanalytical applications. To increase surface hydrophilicity and reduce protein adsorption, COC surfaces were photografted with poly(ethylene glycol) methacrylate (PEGMA) using a two-step sequential approach: covalently-bound surface initiators were formed in the first step and graft polymerization of PEGMA was then carried out from these sites in the second step. Contact angle measurements were used to monitor and quantify the changes in surface hydrophilicity as a function of grafting conditions. As water droplet contact angles decreased from 88 degrees for native COC to 45 degrees for PEGMA-grafted surfaces, protein adsorption was also reduced by 78% for the PEGMA-modified COC microchannels as determined by a fluorescence assay. This photografting technique should enable the use of COC microdevices in a variety of bioanalytical applications that require minimal nonspecific adsorption of biomolecules.     

Micropatterning of Sol-Gel Derived Thin Films Using Hydrophobic-Hydrophilic Patterned Surface

Formation process of convexly shaped oxide micropatterns using hydrophobic-hydrophilic patterned surface has been examined, and this technique was applied to several oxide thin films such as SnO₂, ZrO₂, TiO₂ and Al₂O₃. Hydrophobic-hydrophilic patterned surfaces were prepared on glass substrates by selective UV irradiation through a photomask on double-layered films of a very thin TiO₂ gel film as the underlayer and a hydrolyzed fluoroalkyltrimethoxysilane layer as the top layer. Precursor solutions were then spin-coated on the hydrophobic-hydrophilic patterns, and the coated substrates were dried at room temperature. The micropatterns of oxides were very difficult to be formed on the hydrophobic-hydrophilic patterned surfaces from metal-alkoxides as a precursor solution, but convexly shaped micropatterns were formed on the hydrophilic regions of the pattern when metal chlorides or oxychlorides were used as starting materials. This patterning technique potentially has a wide variety of applications such as fabrication of micro-optical components and finely patterned transparent electrodes.     

Microfluidics meets soft layer-by-layer films: selective cell growth in 3D polymer architectures

We present here the micropatterns of layer-by-layer (LbL) assembled soft films generated using microfluidic platform that can be exploited for selective cell growth. Using this method, the issue of cell adhesion and spreading on soft LbL-derived films, and simultaneous utilisation of such unmodified soft films to exploit their reservoir properties are addressed. This also paves the way for extending the culture of cells to soft films and other demanding applications like triggered release of biomolecules.     

New approach to writing and simultaneous reading of micropatterns: combining surface plasmon resonance imaging with scanning electrochemical microscopy (SECM)

This work establishes the compatibility of surface plasmon resonance imaging (SPR-i) with the visualization of localized electropolymerization. The "writing" of polypyrrole and polypyrrole-oligonucleotide patterns onto thin gold films is demonstrated using scanning electrochemical microcopy (SECM), while an optical method, SPR-i, simultaneously detected the formed micropatterns. The combination of these two methods, SECM/SPR-i, has the advantage of not only controlling the patterning process but also providing unique information on the micropattern formation. The influence of the pulsing time and the monomer concentration on the spot size and its characteristics has been investigated in detail using SPR-i. Fluorescence microscopy and atomic force microscopy have also been used to support the data obtained by SPR-i.     

Surface characterization and properties of plasma‐modified cyclic olefin copolymer/layered silicate nanocomposites

In this study, cyclic olefin copolymer (COC)/layered silicate nanocomposites (CLSNs) were prepared by the intercalation of COC polymer into organically‐modified layered silicate through the solution mixing process. Both X‐ray diffraction data and transmission electron microscopy images of CLSNs indicate most of the swellable silicate layers were disorderedly intercalated into the COC matrix. The effect of layered silicate on the mechanical and barrier properties of the fabricated nanocomposites shows significant improvements in the storage modulus and water permeability when compared with that of neat COC matrix. Surfaces of COC and CLSN films were modified by a mixture of oxygen (O₂) and nitrogen (N₂) plasmas with various treated times, system pressures, and radio frequency (RF) powers. The surfaces of plasma‐modified COC and CLSN were investigated using scanning probe microscopy and contact‐angle measurements. The exposure of the COC and CLSN film to the plasmas led to the combination of etching reactions of polymer surface initiated by plasma and the following addition reactions of new functional groups onto polymer surfaces to change the topology of COC film surfaces. The surface roughness was closely related to how high and how long the RF power was input into the system. The plasmas also led to changes in the surface properties of the CLSN surfaces from hydrophobic to hydrophilic; and the contact angle of water on the surface decreases. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 2745–2753, 2005     

Engineering the surface properties of microfluidic stickers

We introduce a simple and effective method to tailor the wetting and adhesion properties of thiolene-based microfluidic devices. This one-step lithographic scheme combines most of the advantages offered by the current methods employed to pattern microchannels: (i) the channel walls can be modified in situ or ex situ, (ii) their wettability can be varied in a continuous manner, (iii) heterogeneous patterning can be easily accomplished, with contact-angle contrasts extending from 0 to 90° for pure water, (iv) the surface modification has proven to be highly stable upon aging and heating. We first characterize the wetting properties of the modified surfaces. We then provide the details of two complementary methods to achieve surface patterning. Finally, we demonstrate the two methods with three examples of applications: the capillary guiding of fluids, the production of double emulsions, and the culture of cells on adhesive micropatterns.     

微图案化钙磷盐膜层的电化学构筑及其生物性能

基于表面分子自组装和光催化转印技术,在TiO2膜层表面获得超亲/超疏水阵列微图案模板,结合电化学沉积技术,成功制备了微图案化钙磷盐膜(CaP)层.扫描电子显微镜(SEM)和电子探针分析(EPMA)结果表明,通过超亲/超疏水阵列微图案模板可构筑高空间分辨的微图案化钙磷盐膜层.微图案化钙磷盐膜层的体外MG-63细胞培养证实,细胞对钙磷盐膜层微单元有强烈的选择性粘附作用,从而可望控制细胞在微单元中的贴壁生长,实现高通量评价细胞行为.     

The influence of aging on surface free energy of corona treated packaging films

In packaging, plastic films are very often applied as overprinting materials. The printing properties of plastic films depend on the value of the surface free energy. Usually, during storage but before printing, the surface free energy is decreasing as a result of ageing. The aim of this study was to analyse the influence of elevated temperature and UV radiation on ageing properties and variation of the free surface energy for three commercially available plastic films: polyethylene, polypropylene and polyethylene terephthalate. The investigation was done experimentally, and the surface free energy was calculated using two approaches, Owens-Wendt and van Oss-Chaudhury-Good. The time change of polar fractions was also analysed. The calculation results were compared and it was concluded that UV radiation causes more changes in surface free energy than elevated temperature. In some cases, surface free energy values calculated with the applied methods show similar trends.     

Structure and mobility of lipid membranes on a thermoplastic substrate

Supported lipid membranes constitute one of the most important model systems for cell membranes. The properties of lipid membranes supported by the hydrophobic solid polymer cyclic olefin copolymer (COC) were investigated. Lipid layers consisting of varying amounts of 1,2-dioleoyl-3-trimethylammonium propane (DOTAP, cationic) and 1,2-dioleoyl-sn-glycero-3-phosphocholine (DOPC, neutral) prepared by vesicle fusion and solvent exchange were compared. All lipid mixtures coated the COC surface homogeneously forming a fluid membrane as verified by fluorescence microscopy and fluorescence recovery after photobleaching (FRAP). The exact structure of the supported membranes was determined by synchrotron reflectivity experiments using a microfluidic chamber. The X-ray data are in agreement with a compressed (head-to-head distance = 29 angstroms) and less densely packed bilayer.     

Resist-free patterning of surface architectures in polymer-based microanalytical devices

The ability to form patterns of chemically reactive surface functionalities in microanalytical devices using a simple photopatterning approach without the need for photoresist-based methods is described. Direct UV exposure of the surfaces of poly(methyl methacrylate), PMMA, and poly(carbonate), PC, microfluidic devices through optical masks leads to the production of patterns of near monolayer quantities of surface carboxylic acid groups as determined by surface coverage, X-ray photoelectron spectroscopy, and fluorescence microscopy experiments. Formation of the reactive carboxylic acid groups without significant physical (topographical) damage to the polymer device substrates is achieved by use of low UV fluence and exposure times. Modification of the patterned, surface carboxylic acid groups with metals, thermally responsive polymers, and antibodies results in microfluidic devices possessing metallic interconnects and detection electrodes and the ability to capture intact biological cells and proteins from solution.     

Lamination-based rapid prototyping of microfluidic devices using flexible thermoplastic substrates

Transposing highly sensitive DNA separation methods (such as DNA sequencing with high read length or the detection of point mutations) to microchip format without loss of resolution requires fabrication of relatively long (approx. 10 cm) microchannels along with sharp injection bands. Conventional soft lithography methods, such as mold casting or hot-embossing in a press, are not convenient for fabricating long channels. We have developed a lamination-based replication technique for rapid fabrication of sealed microfluidic devices with a 10 cm long, linear separation channel. These devices are fabricated in thin cyclo-olefin copolymer (COC) plastic substrates, thus making the device flexible and capable of assuming a range of 3-D configurations. Due to the good optical properties of COC, this new family of devices combines multiple advantages of planar microfluidics and fused-silica capillaries.     

Chemically resistant microfluidic valves from Viton® membranes bonded to COC and PMMA

We present a reliable technique for irreversibly bonding chemically inert Viton? membranes to PMMA and COC substrates to produce microfluidic devices with integrated elastomeric structures. Viton? is widely used in commercially available valves and has several advantages when compared to other elastomeric membranes currently utilised in microfluidic valves (e.g. PDMS), such as high solvent resistance, low porosity and high temperature tolerance. The bond strength was sufficient to withstand a fluid pressure of 400 kPa (PMMA/Viton?) and 310 kPa (COC/Viton?) before leakage or burst failure, which is sufficient for most microfluidic applications. We demonstrate and characterise on-chip pneumatic Viton? microvalves on PMMA and COC substrates. We also provide a detailed method for bonding fluorinated Viton? elastomer, a highly chemically compatible material, to PMMA and COC polymers. This allows the production of microfluidic devices able to handle a wide range of chemically harsh fluids and broadens the scope of the microfluidic platform concept.     

Fabrication and characterization of stable ultrathin film micropatterns containing DNA and photosensitive polymer diazoresin

Stable, ultrathin DNA micropatterns were fabricated from photosensitive polymer diazoresin (DR) through a self-assembly technique. The micropatterns were achieved on LBL ultrathin film after UV exposure through a photomask. The patterns were characterized systematically with scanning electron microscopy, atomic force microscopy, X-ray photoelectron spectroscopy and fluorescence microscopy. All of the results indicate that the combined LBL self-assembly and photolithography technique is a promising method for constructing stable, well-defined micropatterns with a nanoscale thickness.     

Isoelectric focusing in cyclic olefin copolymer microfluidic channels coated by polyacrylamide using a UV photografting method

As an alternative material to glass or silicon, microfluidic devices made from a cyclic olefin copolymer (COC) were fabricated. This material is of interest because of the relative ease of fabrication, low costs, and solvent resistance. However, as a result of the strong hydrophobic interactions normally present, COC surfaces are not suitable for protein separations. To reduce the protein adsorption and make COC suitable for protein separations, UV-initiated grafting of polyacrylamide was used to coat the surface of COC devices. The change in surface properties caused by different graft times was studied. The surface hydrophilicity and electroosmotic mobility were characterized by contact angle and electroosmosis measurements. Isoelectric focusing was performed to test protein separations in polyacrylamide-coated COC microchannels. A single protein, carbonic anhydrase, was used to analyze the focusing effects and peak capacities in uncoated and polyacrylamide-coated COC devices. Peak capacities ranging from 75 to 190 were achieved with a polyacrylamide-coated surface. A mixture of two proteins, conalbumin labeled with Alexa Fluor 488 and beta-lactoglobulin A labeled with Alexa Fluor 546, was used to test protein separations. Linear and rapid separation of proteins was achieved in the polyacrylamide-coated COC microfluidic device.