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<p>This study presents an optimized fabrication approach for producing master molds for droplet‑generating microfluidic devices using reverse CO₂ laser engraving on polymethyl methacrylate (PMMA) substrates. The method aims to support drug delivery system (DDS) applications by enabling precise control over microchannel geometry and surface quality. Four candidate materials—copper (Cu), aluminum (Al), corrosion‑resistant steel (CRES), and polymethyl methacrylate (PMMA) —are evaluated for engraving quality, cost, and preparation time, in which PMMA is selected for its minimal defects, optical transparency, and ease of processing. Laser parameters are systematically optimized by varying power (10–100%) and scanning speed (200–2000&#xa0;mm s⁻¹) across channel widths from 0.15 to 0.70&#xa0;mm. Optimal conditions of 60% power and 800&#xa0;mm s⁻¹ produced well‑defined trapezoidal channels with heights of 350–400&#xa0;μm and minimal thermal damage. Design limit tests identified curved channel geometries, particularly with a 4&#xa0;mm radius, as superior for stable flow and droplet formation compared to sharp‑angled designs. Surface post‑processing with a nail polish–ethyl acetate mixture (1:2 ratio) effectively reduced roughness without altering channel dimensions. The fabricated PDMS replicas demonstrated high fidelity to the master mold, and assembled devices exhibited smooth, leak‑free fluid flow in dye tests. This single‑step, mold‑based laser engraving process offers a rapid, cost‑effective, and reproducible route to high‑quality microfluidic devices, with potential for broad biomedical applications including targeted drug delivery, nanoparticle synthesis, and lab‑on‑a‑chip systems.</p>

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Fabrication of micro-droplet generating microfluidic master mold using reverse laser engraving

  • 期刊论文

  • 发表日期：

    2026年2月14日

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  • Quan Truong Nguyen,
  • Uyen Thu Pham,
  • Duong Thanh Nguyen,
  • Ngoan Thanh Tran,
  • Linh Diep Dang,
  • Hieu Minh Hoang,
  • Doanh Van Nguyen

摘要

This study presents an optimized fabrication approach for producing master molds for droplet‑generating microfluidic devices using reverse CO₂ laser engraving on polymethyl methacrylate (PMMA) substrates. The method aims to support drug delivery system (DDS) applications by enabling precise control over microchannel geometry and surface quality. Four candidate materials—copper (Cu), aluminum (Al), corrosion‑resistant steel (CRES), and polymethyl methacrylate (PMMA) —are evaluated for engraving quality, cost, and preparation time, in which PMMA is selected for its minimal defects, optical transparency, and ease of processing. Laser parameters are systematically optimized by varying power (10–100%) and scanning speed (200–2000 mm s⁻¹) across channel widths from 0.15 to 0.70 mm. Optimal conditions of 60% power and 800 mm s⁻¹ produced well‑defined trapezoidal channels with heights of 350–400 μm and minimal thermal damage. Design limit tests identified curved channel geometries, particularly with a 4 mm radius, as superior for stable flow and droplet formation compared to sharp‑angled designs. Surface post‑processing with a nail polish–ethyl acetate mixture (1:2 ratio) effectively reduced roughness without altering channel dimensions. The fabricated PDMS replicas demonstrated high fidelity to the master mold, and assembled devices exhibited smooth, leak‑free fluid flow in dye tests. This single‑step, mold‑based laser engraving process offers a rapid, cost‑effective, and reproducible route to high‑quality microfluidic devices, with potential for broad biomedical applications including targeted drug delivery, nanoparticle synthesis, and lab‑on‑a‑chip systems.