Microfluidics

Functional Integration for Rapid Realization of Microreactors and Bio-assays

Background and main goal

Microfluidic systems have been an important area of focus especially for the medtech and biotech industry. One example is the realization of high-throughput rapid diagnostics where microfluidics allows for the analysis of small volumes of material with the promise of increased assay sophistication and accuracy. However, microfluidics manufacturing as it exists today has several restrictions that are ripe for exploitation through advanced manufacturing paradigms.

The Microfluidics project will develop a technology suite for the realization of integrated microfluidic device platforms such as microreactors and bio-assay systems. The technology will be built around novel low-temperature glasses and piezoelectric materials that are suitable for 3D printing and embossing to realize fully-integrated functional systems. Processes will be developed to ensure high-throughput production, including 3D printing and embossing of the novel glass materials, additive manufacturing of active microfluidic components, monolithic component placement and attachment of electronics, along with optical sintering to ensure overall process and material compatibility.

Idea and approach

The Microfluidics project will address all issues related to manufacturing viability – from materials development through cost-efficient processes and monolithic integration of components to complete demonstrators:

Materials for additive processing: Three types of materials for additive processing of functional microfluidics will be developed: (i) iron-doped phosphate glass as the main microfluidic structural material, (ii) piezoelectric materials to facilitate the operation of valves and pumps, and (iii) conductor materials to provide conductors for devices and electrodes.
Patterning of glass: Two approaches will be followed for creating microfluidic structures in glass: (i) thermal imprinting / embossing for microfluidic-channels and (ii) extrusion-based process to print glass microfluidics on demand.
Photonic sintering of materials: Processes for photonic sintering will be developed which will allow sintering with reduced temperature interaction compared to conventional thermal annealing. These processes will be specifically tailored to glass and lead zirconate titanate (PZT).
Heterogeneous integration of semiconductor components: The technology to allow embedding of active semiconductor components within a 3D glass microfluidic framework will be developed. This will allow for the realization of sensing and stimulation within the microfluidic systems.

Demonstrators

Microfluidic formulator: This device will enable the monitoring and assessment of protein phase transitions and aggregation. As a technology driver, it will drive the integration of glass-based microchannels. The device will consist of multiple functional components, with bespoke feature sizes.

Programmable microfluidic platform for protein extraction from single cells: The platform will comprise conduits, chambers, valves and pumps within a monolithic system. Feature sizes will be defined according to the requirements of the analytical process, e.g., throughput and assay time.

Imaging flow cytometry platform: This platform will comprise microfluidic and optical components. Successful integration will allow the realization of a high-throughput smartphone-based imaging flow cytometry platform with brightfield and fluorescence detection capabilities.

Technical challenges

The Microfluidics project will address several challenges that exist in today’s manufacturing of microfluidic systems:

Microfluidic systems are manufactured using subtractive techniques known from the microelectronics industry. Microfluidics, however, is characterized by having relatively low-volume assays and low-spatial density. The high resolution and pattern density offered by semiconductor processes is not required for microfluidics and raises the manufacturing cost significantly.
Microfluidics in research typically makes use of materials that are not viable for medical devices, such as polydimethylsiloxane (PDMS). Integration with medically relevant materials, such as glass, is more complicated, and the maturity of manufacturing technology is lagging.
Functional integration in microfluidic systems is largely achieved through complicated post-assembly. This increases the overall complexity of manufacturing and raises the cost of the final system while at the same time reducing the overall robustness and reliability.

Consortium