Zweifach-Fung Microfluidic Device for Efficient Microparticle Separation: Cost-Effective Fabrication Using CO2 Laser-Ablated PMMA

Microfluidic separators play a pivotal role in the biomedical and chemical industries by enabling precise fluid manipulations. Traditional fabrication of these devices typically requires costly cleanroom facilities, which limits their broader application. This study introduces a novel microfluidic device that leverages the passive Zweifach-Fung principle to overcome these financial barriers. Through Lagrangian computational simulations, we optimized an eleven-channel Zweifach-Fung configuration that achieved a perfect 100% recall rate for particles following a specified normal distribution. Experimental evaluations determined 2 mL/h as the optimal total flow rate (TFR), under which the device showcased exceptional performance enhancements in precision and recall for micrometer-sized particles, achieving an overall accuracy of 94% ± 3%. Fabricated using a cost-effective, non-cleanroom method, this approach represents a significant shift from conventional practices, dramatically reducing production costs while maintaining high operational efficacy. The cost of each chip is less than USD 0.90 cents and the manufacturing process takes only 15 min. The development of this device not only makes microfluidic technology more accessible but also sets a new standard for future advancements in the field.

Rapid Prototyping of Multi-Functional and Biocompatible Parafilm®-Based Microfluidic Devices by Laser Ablation and Thermal Bonding

In this paper, we report a simple, rapid, low-cost, biocompatible, and detachable microfluidic chip fabrication method for customized designs based on Parafilm^®. Here, Parafilm^® works as both a bonding agent and a functional membrane. Its high ultimate tensile stress (3.94 MPa) allows the demonstration of high-performance actuators such as microvalves and micropumps. By laser ablation and the one-step bonding of multiple layers, 3D structured microfluidic chips were successfully fabricated within 2 h. The consumption time of this method (~2 h) was 12 times less than conventional photolithography (~24 h). Moreover, the shear stress of the PMMA-Parafilm^®-PMMA specimens (0.24 MPa) was 2.13 times higher than that of the PDMS-PDMS specimens (0.08 MPa), and 0.56 times higher than that of the PDMS-Glass specimens (0.16 MPa), showing better stability and reliability. In this method, multiple easily accessible materials such as polymethylmethacrylate (PMMA), PVC, and glass slides were demonstrated and well-incorporated as our substrates. Practical actuation devices that required high bonding strength including microvalves and micropumps were fabricated by this method with high performance. Moreover, the biocompatibility of the Parafilm^®-based microfluidic devices was validated through a seven-day E. coli cultivation. This reported fabrication scheme will provide a versatile platform for biochemical applications and point-of-care diagnostics.

Current Challenges and Future Trends of Enzymatic Paper-Based Point-of-Care Testing for Diabetes Mellitus Type 2

A point-of-care (POC) can be defined as an in vitro diagnostic test that can provide results within minutes. It has gained enormous attention as a promising tool for biomarkers detection and diagnosis, as well as for screening of chronic noncommunicable diseases such as diabetes mellitus. Diabetes mellitus type 2 is one of the metabolic disorders that has grown exponentially in recent years, becoming one of the greatest challenges to health systems. Early detection and accurate diagnosis of this disorder are essential to provide adequate treatments. However, efforts to reduce incidence should remain not only in these stages but in developing continuous monitoring strategies. Diabetes-monitoring tools must be accessible and affordable; thus, POC platforms are attractive, especially paper-based ones. Paper-based POCs are simple and portable, can use different matrixes, do not require highly trained staff, and are less expensive than other platforms. These advantages enhance the viability of its application in low-income countries and hard-to-reach zones. This review aims to present a critical summary of the main components required to create a sensitive and affordable enzymatic paper-based POC, as well as an oriented analysis to highlight the main limitations and challenges of current POC devices for diabetes type 2 monitoring and future research opportunities in the field.

A Fluidics-Based Biosensor to Detect and Characterize Inhibition Patterns of Organophosphate to Acetylcholinesterase in Food Materials

A chip-based electrochemical biosensor is developed herein for the detection of organophosphate (OP) in food materials. The principle of the sensing platform is based on the inhibition of dimethoate (DMT), a typical OP that specifically inhibits acetylcholinesterase (AChE) activity. Carbon nanotube-modified gold electrodes functionalized with polydiallyldimethylammonium chloride (PDDA) and oxidized nanocellulose (NC) were investigated for the sensing of OP, yielding high sensitivity. Compared with noncovalent adsorption and deposition in bovine serum albumin, bioconjugation with lysine side chain activation allowed the enzyme to be stable over three weeks at room temperature. The total amount of AChE was quantified, whose activity inhibition was highly linear with respect to DMT concentration. Increased incubation times and/or DMT concentration decreased current flow. The composite electrode showed a sensitivity 4.8-times higher than that of the bare gold electrode. The biosensor was challenged with organophosphate-spiked food samples and showed a limit of detection (LOD) of DMT at 4.1 nM, with a limit of quantification (LOQ) at 12.6 nM, in the linear range of 10 nM to 1000 nM. Such performance infers significant potential for the use of this system in the detection of organophosphates in real samples.

Cutting and Bonding Parafilm® to Fast Prototyping Flexible Hanging Drop Chips for 3D Spheroid Cultures

A fast and low-cost fabrication process of flexible hanging drop chips for 3D spheroid cultures was proposed by cutting and bonding Parafilm®, a cohesive thermoplastic. The Parafilm® Hanging Drop Chip (PHDC) was assembled by two-layer of Parafilm® sheet with different sizes of holes. The hole on the upper layer of the Parafilm® is smaller than the hole on the bottom layer. The impact of hole size and sample volume on hanging drop formation and 3D spheroid formations in the hanging drop were investigated. The results showed that 20 µL solution on PHDC with a 3 mm hole could form stabile drop and facilitate spheroid formation. The initial cell number determinates the size of the formed spheroids. Exchanging liquid from the upper hole of the PHDC enables the co-culture of two types of cells in one spheroid and drug efficacy testing in hanging drops. The relative expression of cell adhesion and hypoxia-related genes from spheroids in hanging drop and conventional culture plate suggested the relevance of 3D spheroids and in vivo tumor tissue. The economical hanging drop chip can be fabricated without wet chemistry or expensive fabrication equipment, strengthening its application potential in conventional biological laboratories.

Adhesive tape-assisted etching of silk fibroin film with LiBr aqueous solution for microfluidic devices

The regenerated silk fibroin (RSF)-based microfluidic device has attracted tremendous interests in recent years due to its excellent biocompatibility, mild processing conditions, and all aqueous casting production. However, the need of a micro-fabricated mold in the manufacture process greatly hinder its practical applications. Herein, we introduce an adhesive tape-assisted etching method with LiBr solution as the etchant to prepare RSF microfluidic devices. An engraved adhesive tape is used as the mask to cover on the surface of a RSF film. Then, LiBr solution is dropped on the mask to etch RSF in concentration- and duration-dependent manners. During this process, the LiBr-treated RSF transits from insoluble β-sheet crystallites to soluble conformations. The as-prepared RSF microfluidic devices possess good chemical resistance and excellent tolerance to mechanical deformation. RSF microfluidic systems with different patterns were fabricated to demonstrate the universality of the approach. A concentration gradient generator and a blood vessel-like channel were manufactured for the preparation of solutions with gradient pHs and the growth of living cells, respectively. The proposed strategy has great potentials in the facile fabrication of low-cost RSF microfluidic devices for tissue engineering and biomedical analysis.

Microfluidics for the study of mechanotransduction

Mechanical forces regulate a diverse set of biological processes at cellular, tissue, and organismal length scales. Investigating the cellular and molecular mechanisms that underlie the conversion of mechanical forces to biological responses is challenged by limitations of traditional animal models and in vitro cell culture, including poor control over applied force and highly artificial cell culture environments. Recent advances in fabrication methods and material processing have enabled the development of microfluidic platforms that provide precise control over the mechanical microenvironment of cultured cells. These devices and systems have proven to be powerful for uncovering and defining mechanisms of mechanotransduction. In this review, we first give an overview of the main mechanotransduction pathways that function at sites of cell adhesion, many of which have been investigated with microfluidics. We then discuss how distinct microfluidic fabrication methods can be harnessed to gain biological insight, with description of both monolithic and replica molding approaches. Finally, we present examples of how microfluidics can be used to apply both solid forces (substrate mechanics, strain, and compression) and fluid forces (luminal, interstitial) to cells. Throughout the review, we emphasize the advantages and disadvantages of different fabrication methods and applications of force in order to provide perspective to investigators looking to apply forces to cells in their own research.

Desktop Fabrication of Lab-On-Chip Devices on Flexible Substrates: A Brief Review

Flexible microfluidic devices are currently in demand because they can be mass-produced in resource-limited settings using simple and inexpensive fabrication tools. Finding new ways to fabricate microfluidic platforms on flexible substrates has been a hot area. Integration of customized detection tools for different lab-on-chip applications has made this area challenging. Significant advancements have occurred in the area over the last decade; therefore, there is a need to review such interesting fabrication tools employed on flexible substrates, such as paper and plastics. In this short review, we review individual fabrication tools and their combinations that have been used to develop such platforms in the past five years. These tools are not only simple and low-cost but also require minimal skills for their operation. Moreover, key examples of plastic-based flexible substrates are also presented, because a diverse range of plastic materials have prevailed recently for a variety of lab-on-chip applications. This review should attract audience of various levels, i.e., from hobbyists to scientists, and from high school students to postdoctoral researchers, to produce their own flexible devices in their own settings.

Smartphone supported backlight illumination and image acquisition for microfluidic-based point-of-care testing

A smartphone-based image analysis system is advantageous for point-of-care testing applications. However, the processes of observation and image recording rely heavily on an external attachment that includes additional light sources. Moreover, microfluidic point-of-care devices are highly miniaturized, and can be clearly observed only under magnification. To address these issues, the present work proposes a novel imaging box for converting the built-in light source of a smartphone into uniform backlight illumination to avoid interference arising from reflections. A multi-piece orthoscopic lens is embedded in the imaging box to enable the imaging of micro-sized samples. As such, the colorimetric signal of a microchannel with a width as small as 25 µm can be faithfully recorded. Protein concentration quantification based on the bicinchoninic acid assay method was demonstrated with the proposed smartphone/imaging box system from an analysis of colorimetric signals. In addition, a microfluidic chip for conducting ABO blood typing was fabricated, and the microscopic imaging of induced blood coagulation can be clearly observed in a 3 µL sample using the proposed system. These results highlight the potential for adopting smartphone-based analysis systems in point-of-care testing applications.