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<p>3D printed microfluidic systems have demonstrated their potentials in biomedical engineering, especially in the fields of drug delivery and tissue engineering. In this study, we report the design and fabrication of microfluidic chips using masked stereolithography (MSLA). The chip design includes three inlet ports, drug carrier loading ports, independent microchannels within the resin chip, and exit ports for waste fluids from the chip. Individual liquid reservoirs near the exit ports of the microchannels serve as reservoirs for up to 70 µL of the drug-containing liquid samples to be collected and further processed by a spectrophotometer. To facilitate the design, systematic studies were performed on printing parameters, minimum channel width, chip base plate warpages, and channel geometry of the channels. Results show that a light exposure of 2&#xa0;s, a layer thickness of 0.05&#xa0;mm, and a curing time of 5&#xa0;min were ideal for the consistent reproduction of the microfluidic chips without defects. Circular channels with a 1&#xa0;mm diameter produced uniform internal fluid channels without clogging and geometric deformation, while 5-mm thick chip base plates were used to balance warpage and design. Furthermore, metamaterial designs were incorporated into the chip base plates for simulation studies on chip base plate warpage, and results suggested that solid chips performed better than those with metamaterial designs. Overall, our study demonstrates the use of 3D resin printing for rapid prototyping on customizable geometries with a cost-efficient solution to address the limitations of traditional soft lithography in the manufacturing of microfluidic chips.</p>

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Design and 3D Resin Printing of Microfluidic Chips for In-Vitro Drug Release Assays

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Preston Miller,
  • Hamed Hosseinzadeh,
  • Shih-Feng Chou

摘要

3D printed microfluidic systems have demonstrated their potentials in biomedical engineering, especially in the fields of drug delivery and tissue engineering. In this study, we report the design and fabrication of microfluidic chips using masked stereolithography (MSLA). The chip design includes three inlet ports, drug carrier loading ports, independent microchannels within the resin chip, and exit ports for waste fluids from the chip. Individual liquid reservoirs near the exit ports of the microchannels serve as reservoirs for up to 70 µL of the drug-containing liquid samples to be collected and further processed by a spectrophotometer. To facilitate the design, systematic studies were performed on printing parameters, minimum channel width, chip base plate warpages, and channel geometry of the channels. Results show that a light exposure of 2 s, a layer thickness of 0.05 mm, and a curing time of 5 min were ideal for the consistent reproduction of the microfluidic chips without defects. Circular channels with a 1 mm diameter produced uniform internal fluid channels without clogging and geometric deformation, while 5-mm thick chip base plates were used to balance warpage and design. Furthermore, metamaterial designs were incorporated into the chip base plates for simulation studies on chip base plate warpage, and results suggested that solid chips performed better than those with metamaterial designs. Overall, our study demonstrates the use of 3D resin printing for rapid prototyping on customizable geometries with a cost-efficient solution to address the limitations of traditional soft lithography in the manufacturing of microfluidic chips.