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<p>The presented paper employed the Fused Filament Fabrication (FFF) 3D printing technique in fabricating a transparent microchannel-array, as a monolithic structure to possess a high strength and plasma extraction capability. The research is dedicated to addressing the challenge of the design complexity of the SLA/DLP technique, higher surface roughness, and weaker mechanical strength of the FFF technique, when feature sizes go down to the microscale level. Products related to biomedical applications, such as Lab-on-Chip (LOC) biosensing devices, consist of micro features and microstructures for bioseparation, biomixing, and bifurcations, depending upon the underlying principle employed. By eliminating all sorts of post-processing, we have fabricated a microchannel structure that could be applicable to biomedical applications, avoiding sample contamination. The paper also highlights certain slicing parameters related to infill and raster angle, which play a profound role in achieving defined micromachining dimensions and satisfactory strength. roughness, wettability, and transparency. We have successfully fabricated open microchannel ranging from a minimum average channel width (Wd) of 240.625&#xa0;μm to a maximum of 428.052&#xa0;μm, and a minimum average channel depth (Wd) ranging from 20.625&#xa0;μm to 100.568&#xa0;μm. The fabricated disposable plasma extractor reports a mean average roughness of 0.153&#xa0;μm along the microchannel length, while the surface contact angle average value is reported to be 54.7°, and exhibits maximum transmittance of 59.74% (Front) and 64.96% (Back) at wavelength 800&#xa0;nm with raster angles 0° and 90°. The reported results satisfactorily test a working plasma extractor that extracted 50&#xa0;µl of pure plasma from 1&#xa0;ml of whole blood in 10&#xa0;min, giving a theoretical extraction rate of 0.083&#xa0;µl/sec. The successful cases are reported for the V-Shaped microchannel having R/G &gt; 1.</p>

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Design and Fabrication of Open Microchannel-Arrays Using FFF 3D Printing Technique for On-Chip Membrane-based Rapid Plasma Extraction

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • Shamima Khatoon,
  • Gufran Ahmad,
  • Manju Srivastava

摘要

The presented paper employed the Fused Filament Fabrication (FFF) 3D printing technique in fabricating a transparent microchannel-array, as a monolithic structure to possess a high strength and plasma extraction capability. The research is dedicated to addressing the challenge of the design complexity of the SLA/DLP technique, higher surface roughness, and weaker mechanical strength of the FFF technique, when feature sizes go down to the microscale level. Products related to biomedical applications, such as Lab-on-Chip (LOC) biosensing devices, consist of micro features and microstructures for bioseparation, biomixing, and bifurcations, depending upon the underlying principle employed. By eliminating all sorts of post-processing, we have fabricated a microchannel structure that could be applicable to biomedical applications, avoiding sample contamination. The paper also highlights certain slicing parameters related to infill and raster angle, which play a profound role in achieving defined micromachining dimensions and satisfactory strength. roughness, wettability, and transparency. We have successfully fabricated open microchannel ranging from a minimum average channel width (Wd) of 240.625 μm to a maximum of 428.052 μm, and a minimum average channel depth (Wd) ranging from 20.625 μm to 100.568 μm. The fabricated disposable plasma extractor reports a mean average roughness of 0.153 μm along the microchannel length, while the surface contact angle average value is reported to be 54.7°, and exhibits maximum transmittance of 59.74% (Front) and 64.96% (Back) at wavelength 800 nm with raster angles 0° and 90°. The reported results satisfactorily test a working plasma extractor that extracted 50 µl of pure plasma from 1 ml of whole blood in 10 min, giving a theoretical extraction rate of 0.083 µl/sec. The successful cases are reported for the V-Shaped microchannel having R/G > 1.