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Inexpensive, rapid prototyping of microfluidic devices using overhead transparencies and a laser print, cut and laminate fabrication method

Nature Protocols volume 10, pages 875–886 (2015)Cite this article

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Abstract

We describe a technique for fabricating microfluidic devices with complex multilayer architectures using a laser printer, a CO2 laser cutter, an office laminator and common overhead transparencies as a printable substrate via a laser print, cut and laminate (PCL) methodology. The printer toner serves three functions: (i) it defines the microfluidic architecture, which is printed on the overhead transparencies; (ii) it acts as the adhesive agent for the bonding of multiple transparency layers; and (iii) it provides, in its unmodified state, printable, hydrophobic 'valves' for fluidic flow control. By using common graphics software, e.g., CorelDRAW or AutoCAD, the protocol produces microfluidic devices with a design-to-device time of ∼40 min. Devices of any shape can be generated for an array of multistep assays, with colorimetric detection of molecular species ranging from small molecules to proteins. Channels with varying depths can be formed using multiple transparency layers in which a CO2 laser is used to remove the polyester from the channel sections of the internal layers. The simplicity of the protocol, availability of the equipment and substrate and cost-effective nature of the process make microfluidic devices available to those who might benefit most from expedited, microscale chemistry.

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Figure 1: Schematic of the PCL protocol.
Figure 2: CorelDRAW design of a complex microfluidic device and the post-ablation architecture.
Figure 3: Schematic of components required for assembly of a multilayer chip.
Figure 4: Designing the toner valve layer.
Figure 5: Alignment processes associated with laser printing and ablation.
Figure 6: Screenshot image of the VersaLaser VLS3.50 software displaying z-axis tabs.
Figure 7: Screenshot image of the VersaLaser VLS3.50 software showing color and 'vect' options.
Figure 8: Multilayer alignment to yield a functional microdevice.
Figure 9: Different microdevice designs fabricated by the laser PCL protocol.
Figure 10: PCL microdevice-facilitated total protein quantification and white blood cell counting directly from whole blood.

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Acknowledgements

We gratefully acknowledge funding from the US National Institutes of Health grant number 5R01EB011591-04. We also acknowledge invaluable discussions with D. Haverstick and J. Li.

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Authors and Affiliations

  1. Department of Chemistry, University of Virginia, Charlottesville, Virginia, USA

    Brandon L Thompson, Yiwen Ouyang, Shannon T Krauss & James P Landers

  2. Instituto de Química, Universidade Federal De Goiás, Goiânia-Go, Brazil

    Gabriela R M Duarte

  3. Bioanalytical, Microfabrication and Separations Group, Instituto de Química de São Carlos/Universidade de São Paulo, Instituto Nacional de Ciência e Tecnologia de Bioanalítica, São Carlos, Brazil

    Emanuel Carrilho

  4. Department of Mechanical Engineering, University of Virginia, Charlottesville, Virginia, USA

    James P Landers

  5. Department of Pathology, University of Virginia, Charlottesville, Virginia, USA

    James P Landers

Authors
  1. Brandon L Thompson
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  4. Emanuel Carrilho
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Contributions

B.L.T., S.T.K. and Y.O. designed the chips. Y.O. and G.R.M.D. were critical in the development of the early protocol. E.C. helped develop the concept. B.L.T. and Y.O. conducted the experiments. B.L.T., Y.O. and J.P.L. analyzed the data. B.L.T. and J.P.L. wrote the paper.

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Correspondence to James P Landers.

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Thompson, B., Ouyang, Y., Duarte, G. et al. Inexpensive, rapid prototyping of microfluidic devices using overhead transparencies and a laser print, cut and laminate fabrication method. Nat Protoc 10, 875–886 (2015). https://doi.org/10.1038/nprot.2015.051

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