Use of 3D printing to integrate microchip electrophoresis with amperometric detection.

This paper describes the use of PolyJet 3D printing to fabricate microchip electrophoresis devices with integrated microwire electrodes for amperometric detection. The fabrication process involves 3D printing of two separate pieces, a channel layer and an electrode layer. The channel layer is created by 3D printing on a pre-fabricated mold with a T-intersection. For the electrode layer, a stencil design is printed directly on the printing tray and covered with a piece of transparent glass. Microwire electrodes are adhered over the glass piece (guided by underlaying stencil) and a CAD design of the electrode layer is then printed on top of the microwire electrode. After delamination from the glass after printing, the microwire is embedded in the printed piece, with the stencil design ensuring that alignment and positioning of the electrode is reproducible for each print. After a thermal bonding step between the channel layer and electrode layer, a complete electrophoresis device with integrated microelectrodes for amperometric detection results. It is shown that this approach enables different microwire electrodes (gold or platinum) and sizes (100 or 50 µm) to be integrated in an end-channel configuration with no gap between the electrode and the separation channel. These devices were used to separate a mixture of catecholamines and the effect of separation voltage on the potential voltage applied on the working electrode was also investigated. In addition, the effect of electrode size on the number of theoretical plates and limit of detection was studied. Finally, a device that contains different channel heights and a detection electrode was 3D-printed to integrate continuous flow sampling with microchip electrophoresis and amperometric detection.

PolyJet-Based 3D Printing against Micromolds to Produce Channel Structures for Microchip Electrophoresis.

In this work, we demonstrate the ability to use micromolds along with a stacked three-dimensional (3D) printing process on a commercially available PolyJet printer to fabricate microchip electrophoresis devices that have a T-intersection, with channel cross sections as small as 48 × 12 µm2 being possible. The fabrication process involves embedding removable materials or molds during the printing process, with various molds being possible (wires, brass molds, PDMS molds, or sacrificial materials). When the molds are delaminated/removed, recessed features complementary to the molds are left in the 3D prints. A thermal lab press is used to bond the microchannel layer that also contains printed reservoirs against another solid 3D-printed part to completely seal the microchannels. The devices exhibited cathodic electroosmotic flow (EOF), and mixtures of fluorescein isothiocyanate isomer I (FITC)-labeled amino acids were successfully separated on these 3D-printed devices using both gated and pinched electrokinetic injections. While this application is focused on microchip electrophoresis, the ability to 3D-print against molds that can subsequently be removed is a general methodology to decrease the channel size for other applications as well as to possibly integrate 3D printing with other production processes.

Fully 3D printed fluidic devices with integrated valves and pumps for flow injection analysis.

The use of a PolyJet 3D printer to create a microfluidic device that has integrated valves and pumps is described. The process uses liquid support and stacked printing to result in fully printed devices that are ready to use within minutes of fabrication after minimal post-processing. A unique feature of PolyJet printing is the ability to incorporate several different materials of varying properties into one print. In this work, two commercially available materials were used: a rigid-transparent plastic material (VeroClear) was used to define the channel regions and the bulk of the device, while the pumps/valves were printed in a flexible, rubber-like material (Agilus30). The entire process, from initial design to testing takes less than 4 hours to complete. The performance of the valves and pumps were characterized by fluorescence microscopy. A flow injection analysis device that enabled the discrete injections of analyte plugs was created, with on-chip pumps being used to move the fluid streams. The injection process was found to be reproducible and linearly correlated with changes in analyte concentration. The utility was demonstrated with the injection and rapid lysis of fluorescently-labeled endothelial cells. The ability to produce a device with integrated pumps/valves in one process significantly adds to the applicability of 3D printing to create microfluidic devices for analytical measurements.