3D printing monolithic, multifunctional polymer acoustofluidic devices with tunable mixing and particle focusing

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Abstract
Acoustic forces offer a powerful, contact-free modality for manipulating particles and fluids within microfluidic lab-on-a-chip systems. However, realizing the full potential of acoustic manipulation has been constrained by conventional cleanroom-based fabrication methods. Typically formed from high-acoustic-impedance materials like silicon or glass, these processes yield devices with limited design complexity owing to the planar channel geometries inherent in micromachining. Here, we introduce a class of polymer-based acoustofluidic platforms fabricated using micro-digital light processing (μDLP) 3D printing. In contrast to micromachining, this additive manufacturing approach enables complex, truly three-dimensional (3D) microfluidic architectures in a monolithic device form factor. We demonstrate strategies to overcome challenges associated with low-acoustic-impedance polymer resins and establish design rules based on precise control over channel and surrounding material dimensions (e.g., wall thicknesses) to achieve robust acoustofluidic functions including efficient sharp-edge-based mixing and effective particle focusing using a bulk acoustic wave resonance mode. By leveraging the design freedom provided by additive manufacturing, we fabricated an integrated, monolithic device driven by a single piezoelectric element that sequentially performs acoustic mixing and focusing within spatially distinct regions enabled by engineered variations in the 3D channel structure. This work establishes μDLP additive manufacturing as a key enabler for next generation acoustofluidic platforms by demonstrating how true 3D architectural control over channel geometry can yield integrated, multifunctional polymer acoustofluidic devices with an expanded functional design space.
Funding Information
  • Established Program to Stimulate Competitive Research (2229784)
  • NASA Headquarters (80NSSC23K1210)
  • Air Force Office of Scientific Research (W911NF-23-1-0162)
  • Air Force Office of Scientific Research (W911NF-24-1-0278)
  • National Institute of General Medical Sciences (3P20GM113134-07S1)
  • National Institute of General Medical Sciences (5P20GM113134-07)
  • National Institute of General Medical Sciences (T34GM141986)
  • Division of Civil, Mechanical and Manufacturing Innovation (2240170)

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