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Micromachines
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3D-Printed Microdevices: From Design to Applications
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3D-Printed Microdevices: From Design to Applications

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D3: 3D Printing and Additive Manufacturing".

Deadline for manuscript submissions: closed (31 January 2024) | Viewed by 10870

Special Issue Editors

Dr. Cristiane Kalinke

E-Mail Website
Guest Editor
Institute of Chemistry, University of Campinas, Campinas 13083-970, Brazil
Interests: additive manufacturing; 3D-printed sensors; conductive filaments; electroanalysis; sensing
Dr. Rodrigo Alejandro Abarza Munoz

E-Mail Website
Guest Editor
Institute of Chemistry, Federal University of Uberlância, Uberlândia 38408-100, Brazil
Interests: analytical chemistry; electrochemistry; additive manufacturing; nanomaterials; graphene; sensors
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Three-dimensional printing has become an interesting tool for the prototyping and fabrication of new devices and microdevices with versatility, quickness, and low cost. The advent of this technology has also allowed the improvement of manufacturing processes, which enable the fabrication of new designs with higher printing accuracy and lower material expenditure, especially when it comes to miniaturized and portable devices. In this context, high-quality devices can be directly produced in research laboratories, bringing scientific research and industry closer. A wide range of 3D techniques, printers, and materials have been explored for this purpose, depending on the application (i.e., biological, medical, chemical, and engineering, among others). Thus, this Special Issue focuses on the design of new 3D printing microdevices for several applications.

Dr. Cristiane Kalinke
Dr. Rodrigo Alejandro Abarza Munoz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • 3D printing
  • microdevices
  • lab-made prototyping
  • miniaturization
  • portable devices

Published Papers (6 papers)

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Research

17 pages, 4749 KiB  
Article
A Novel 3D-Printed and Miniaturized Periodic Counter Current Chromatography System for Continuous Purification of Monoclonal Antibodies
by Carlotta Kortmann, Taieb Habib, Christopher Heuer, Dörte Solle and Janina Bahnemann
Micromachines 2024, 15(3), 382; https://doi.org/10.3390/mi15030382 - 13 Mar 2024
Viewed by 889
Abstract
Continuous chromatography has emerged as one of the most attractive methods for protein purification. Establishing such systems involves installing several chromatographic units in series to enable continuous separation processes and reduce the cost of the production of expensive proteins and biopharmaceuticals (such as [...] Read more.
Continuous chromatography has emerged as one of the most attractive methods for protein purification. Establishing such systems involves installing several chromatographic units in series to enable continuous separation processes and reduce the cost of the production of expensive proteins and biopharmaceuticals (such as monoclonal antibodies). However, most of the established systems are bulky and plagued by high dead volume, which requires further optimization for improved separation procedures. In this article, we present a miniaturized periodic counter-current chromatography (PCCC) system, which is characterized by substantially reduced dead volume when compared to traditional chromatography setups. The PCCC device was fabricated by 3D printing, allowing for flexible design adjustments and rapid prototyping, and has great potential to be used for the screening of optimized chromatography conditions and protocols. The functionality of the 3D-printed device was demonstrated with respect to the capture and polishing steps during a monoclonal antibody purification process. Furthermore, this novel miniaturized system was successfully used for two different chromatography techniques (affinity and ion-exchange chromatography) and two different types of chromatographic units (columns and membrane adsorbers). This demonstrated versability underscores the flexibility of this kind of system and its potential for utilization in various chromatography applications, such as direct product capture from perfusion cell cultures. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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24 pages, 9900 KiB  
Article
Rapid Micromolding of Sub-100 µm Microfluidic Channels Using an 8K Stereolithographic Resin 3D Printer
by Arpith Vedhanayagam, Michael Golfetto, Jeffrey L. Ram and Amar S. Basu
Micromachines 2023, 14(8), 1519; https://doi.org/10.3390/mi14081519 - 28 Jul 2023
Viewed by 2278
Abstract
Engineering microfluidic devices relies on the ability to manufacture sub-100 micrometer fluidic channels. Conventional lithographic methods provide high resolution but require costly exposure tools and outsourcing of masks, which extends the turnaround time to several days. The desire to accelerate design/test cycles has [...] Read more.
Engineering microfluidic devices relies on the ability to manufacture sub-100 micrometer fluidic channels. Conventional lithographic methods provide high resolution but require costly exposure tools and outsourcing of masks, which extends the turnaround time to several days. The desire to accelerate design/test cycles has motivated the rapid prototyping of microfluidic channels; however, many of these methods (e.g., laser cutters, craft cutters, fused deposition modeling) have feature sizes of several hundred microns or more. In this paper, we describe a 1-day process for fabricating sub-100 µm channels, leveraging a low-cost (USD 600) 8K digital light projection (DLP) 3D resin printer. The soft lithography process includes mold printing, post-treatment, and casting polydimethylsiloxane (PDMS) elastomer. The process can produce microchannels with 44 µm lateral resolution and 25 µm height, posts as small as 400 µm, aspect ratio up to 7, structures with varying z-height, integrated reservoirs for fluidic connections, and a built-in tray for casting. We discuss strategies to obtain reliable structures, prevent mold warpage, facilitate curing and removal of PDMS during molding, and recycle the solvents used in the process. To our knowledge, this is the first low-cost 3D printer that prints extruded structures that can mold sub-100 µm channels, providing a balance between resolution, turnaround time, and cost (~USD 5 for a 2 × 5 × 0.5 cm3 chip) that will be attractive for many microfluidics labs. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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13 pages, 4778 KiB  
Article
Processes for the 3D Printing of Hydrodynamic Flow-Focusing Devices
by Diwakar M. Awate, Seth Holton, Katherine Meyer and Jaime J. Juárez
Micromachines 2023, 14(7), 1388; https://doi.org/10.3390/mi14071388 - 07 Jul 2023
Viewed by 1037
Abstract
Flow focusing is an important hydrodynamic technique for cytometric analysis, enabling the rapid study of cellular samples to identify a variety of biological processes. To date, the majority of flow-focusing devices are fabricated using conventional photolithography or flame processing of glass capillaries. This [...] Read more.
Flow focusing is an important hydrodynamic technique for cytometric analysis, enabling the rapid study of cellular samples to identify a variety of biological processes. To date, the majority of flow-focusing devices are fabricated using conventional photolithography or flame processing of glass capillaries. This article presents a suite of low-cost, millifluidic, flow-focusing devices that were fabricated using a desktop sterolithgraphy (SLA) 3D printer. The suite of SLA printing strategies consists of a monolithic SLA method and a hybrid molding process. In the monolithic SLA approach, 1.3 mm square millifluidic channels were printed as a single piece. The printed device does not require any post processing, such as bonding or surface polishing for optical access. The hybrid molding approach consists of printing a mold using the SLA 3D printer. The mold is treated to an extended UV exposure and oven baked before using PDMS as the molding material for the channel. To demonstrate the viability of these channels, we performed a series of experiments using several flow-rate ratios to show the range of focusing widths that can be achieved in these devices. The experiments are validated using a numerical model developed in ANSYS. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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11 pages, 7151 KiB  
Article
Structure Design and Characterization of 3D Printing System of Thermal Battery Electrode Ink Film
by Fengli Liu, Jiale Lu, Yongping Hao, Yao Chang, Kuaikuai Yu, Shuangjie Liu and Zhiwei Chu
Micromachines 2023, 14(6), 1147; https://doi.org/10.3390/mi14061147 - 29 May 2023
Viewed by 921
Abstract
In this paper, a 3D printing system for a thermal battery electrode ink film is set up and investigated based on the on-demand microdroplet ejection technology. The optimal structural dimensions of the spray chamber and metal membrane of the micronozzle are determined via [...] Read more.
In this paper, a 3D printing system for a thermal battery electrode ink film is set up and investigated based on the on-demand microdroplet ejection technology. The optimal structural dimensions of the spray chamber and metal membrane of the micronozzle are determined via simulation analysis. The workflow and functional requirements of the printing system are set up. The printing system includes a pretreatment system, piezoelectric micronozzle, motion control system, piezoelectric drive system, sealing system, and liquid conveying system. Different printing parameters are compared to obtain optimized printing parameters, which can be attributed to the optimal pattern of the film. The feasibility and controllability of 3D printing methods are verified by printing tests. The size and output speed of the droplets can be controlled by adjusting the amplitude and frequency of the driving waveform acting on the piezoelectric actuator. So, the required shape and thickness of the film can be achieved. An ink film in terms of nozzle diameter = 0.6 mm, printing height = 8 mm, wiring width = 1 mm, input voltage = 3 V and square wave signal frequency = 35 Hz can be achieved. The electrochemical performance of thin-film electrodes is crucial in thermal batteries. The voltage of the thermal battery reaches its peak and tends to flatten out at around 100 s when using this printed film. The electrical performance of the thermal batteries using the printed thin films is found to be stable. This stabilized voltage makes it applicable to thermal batteries. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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16 pages, 9459 KiB  
Article
The Development of a 3D Printer-Inspired, Microgravity-Compatible Sample Preparation Device for Future Use Inside the International Space Station
by Kamfai Chan, Arunkumar Arumugam, Cole Markham, Ryan Jenson, Hao-Wei Wu and Season Wong
Micromachines 2023, 14(5), 937; https://doi.org/10.3390/mi14050937 - 26 Apr 2023
Viewed by 1902
Abstract
Biological testing on the International Space Station (ISS) is necessary in order to monitor the microbial burden and identify risks to crew health. With support from a NASA Phase I Small Business Innovative Research contract, we have developed a compact prototype of a [...] Read more.
Biological testing on the International Space Station (ISS) is necessary in order to monitor the microbial burden and identify risks to crew health. With support from a NASA Phase I Small Business Innovative Research contract, we have developed a compact prototype of a microgravity-compatible, automated versatile sample preparation platform (VSPP). The VSPP was built by modifying entry-level 3D printers that cost USD 200–USD 800. In addition, 3D printing was also used to prototype microgravity-compatible reagent wells and cartridges. The VSPP’s primary function would enable NASA to rapidly identify microorganisms that could affect crew safety. It has the potential to process samples from various sample matrices (swab, potable water, blood, urine, etc.), thus yielding high-quality nucleic acids for downstream molecular detection and identification in a closed-cartridge system. When fully developed and validated in microgravity environments, this highly automated system will allow labor-intensive and time-consuming processes to be carried out via a turnkey, closed system using prefilled cartridges and magnetic particle-based chemistries. This manuscript demonstrates that the VSPP can extract high-quality nucleic acids from urine (Zika viral RNA) and whole blood (human RNase P gene) in a ground-level laboratory setting using nucleic acid-binding magnetic particles. The viral RNA detection data showed that the VSPP can process contrived urine samples at clinically relevant levels (as low as 50 PFU/extraction). The extraction of human DNA from eight replicate samples showed that the DNA extraction yield is highly consistent (there was a standard deviation of 0.4 threshold cycle when the extracted and purified DNA was tested via real-time polymerase chain reaction). Additionally, the VSPP underwent 2.1 s drop tower microgravity tests to determine if its components are compatible for use in microgravity. Our findings will aid future research in adapting extraction well geometry for 1 g and low g working environments operated by the VSPP. Future microgravity testing of the VSPP in the parabolic flights and in the ISS is planned. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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17 pages, 2463 KiB  
Article
A User-Centric 3D-Printed Modular Peristaltic Pump for Microfluidic Perfusion Applications
by Jorge A. Cataño, Steven Farthing, Zeus Mascarenhas, Nathaniel Lake, Prasad K. D. V. Yarlagadda, Zhiyong Li and Yi-Chin Toh
Micromachines 2023, 14(5), 930; https://doi.org/10.3390/mi14050930 - 25 Apr 2023
Cited by 1 | Viewed by 3177
Abstract
Microfluidic organ-on-a-chip (OoC) technology has enabled studies on dynamic physiological conditions as well as being deployed in drug testing applications. A microfluidic pump is an essential component to perform perfusion cell culture in OoC devices. However, it is challenging to have a single [...] Read more.
Microfluidic organ-on-a-chip (OoC) technology has enabled studies on dynamic physiological conditions as well as being deployed in drug testing applications. A microfluidic pump is an essential component to perform perfusion cell culture in OoC devices. However, it is challenging to have a single pump that can fulfil both the customization function needed to mimic a myriad of physiological flow rates and profiles found in vivo and multiplexing requirements (i.e., low cost, small footprint) for drug testing operations. The advent of 3D printing technology and open-source programmable electronic controllers presents an opportunity to democratize the fabrication of mini-peristaltic pumps suitable for microfluidic applications at a fraction of the cost of commercial microfluidic pumps. However, existing 3D-printed peristaltic pumps have mainly focused on demonstrating the feasibility of using 3D printing to fabricate the structural components of the pump and neglected user experience and customization capability. Here, we present a user-centric programmable 3D-printed mini-peristaltic pump with a compact design and low manufacturing cost (~USD 175) suitable for perfusion OoC culture applications. The pump consists of a user-friendly, wired electronic module that controls the operation of a peristaltic pump module. The peristaltic pump module comprises an air-sealed stepper motor connected to a 3D-printed peristaltic assembly, which can withstand the high-humidity environment of a cell culture incubator. We demonstrated that this pump allows users to either program the electronic module or use different-sized tubing to deliver a wide range of flow rates and flow profiles. The pump also has multiplexing capability as it can accommodate multiple tubing. The performance and user-friendliness of this low-cost, compact pump can be easily deployed for various OoC applications. Full article
(This article belongs to the Special Issue 3D-Printed Microdevices: From Design to Applications)
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