Capillary-Driven Microdevice Mixer Using Additive Manufacturing (SLA Technology)

Abstract

This study presents a novel microfluidic mixer designed, fabricated, and characterized using additive manufacturing technology—stereolithography (SLA)—and harnessing capillarity principles achieved through microstructure patterning. Micromixers are integral components in optimizing mixing and reaction processes within microfluidic systems. The proposed microdevice employs a tank mixing method capable of blending two fluids. With a channel length of up to 6 mm, the process time is remarkably swift at 3 s, and the compact device measures 35 × 40 × 5 mm. The capillarity-driven working flow rates range from 1 μL/s to 37 μL/s, facilitated by channel dimensions varying between 400 μm and 850 μm. The total liquid volume within the device channels is 1652 mL (6176 μL including the supply tanks). The mix index, representing the homogeneity of the two fluids, is approximately 0.55 along the main channel. The manufacturing process, encompassing printing, isopropyl cleaning, and UV (ultraviolet) curing, is completed within 90 min. This microfluidic mixer showcases efficient mixing capabilities, rapid processing, and a compact design, marking it as a promising advancement in microfluidic technology. The new microfluidic mixer is a major step forward in microfluidic technology, providing a cost-effective and flexible solution for various uses. Its compatibility with SLA additive manufacturing allows for quick prototyping and design improvements, making it valuable for research and practical applications in chemistry, biology, and diagnostics. This study highlights the importance of combining advanced manufacturing techniques with basic fluid dynamics to create effective and easy-to-use microfluidic solutions.