Print-Aware Synthesis and Physical Design Methodologies for 3D-Printed Microfluidic Biochips
2026-08-17 • Emerging Technologies
Emerging Technologies
AI summaryⓘ
The authors worked on making tiny fluid devices easier and cheaper to build using 3D printing with resin. They created a system that helps design these devices automatically and fixes common printing problems like parts getting too thick or channels getting blocked. Their method also includes tools for making mixers and improving printing precision with affordable printers. This approach aims to simplify both designing and making these complex small devices.
Microfluidics3D printingResin-based printingDesign automationFabricationOver-curingPrototypingMixersPrint fidelity
Authors
Yushen Zhang, Tsun-Ming Tseng, Ulf Schlichtmann
Abstract
Microfluidic devices are widely used in diagnostics, chemical synthesis, and biological analysis, but their development often depends on complex fabrication and design processes. Resin-based three-dimensional (3D) printing has emerged as a promising alternative to conventional microfabrication because it enables low-cost, rapid prototyping of complex multi-layer structures. However, the practical realization of 3D-printed microfluidic biochips remains challenging due to manual and expertise-intensive design workflows, the rigid nature of commonly used printing materials, and fabrication inaccuracies such as over-curing that distort internal features and may block narrow channels. In this paper, we present a cohesive design automation framework for 3D-printed microfluidics that addresses these challenges across both device design and fabrication. The framework combines interactive design tools, automated synthesis methods for functional 3D microfluidic devices, techniques for developing low-cost 3D-printed mixers, and design-for-manufacturing strategies to improve print fidelity on low-cost resin printers.