Castable 3D monolithic microfluidic devices.

Abstract

Microfluidic devices remain difficult to translate into commercial products, particularly for three-dimensional (3D) applications. While soft lithography offers high-resolution features and biocompatibility, its workflows and planar geometries are limited. Conversely, industry-standard injection moulding enables scalability, but lacks flexibility and incurs high upfront costs. Here, we present an innovative hybrid microfabrication methodology combining stereolithographic 3D printed moulds with flexible wire templating and polydimethylsiloxane (PDMS) casting to create monolithic 3D microfluidic devices. Leveraging injection moulding design principles, this enables the rapid and repeatable fab..