Aerosol jet printing process for surface acoustic wave (SAW) microfluidic devices. a schematic of the fabrication process and mechanism of aerosol jet-printed SAW microfluidic devices. The interdigital transducers are fabricated by aerosol jet printing and actuated to create a SAW that propagates within the droplet to allow acoustic forces, including acoustic radiation and acoustic flux, to act on the droplet and particles at inside the droplet. b Image of an aerosol jet printer with a printed PEDOT:PSS SAW microfluidic device. c Image of an interdigital transducer based on silver nanowires on a lithium niobate substrate. d Comparison of timing and number of manufacturing steps between cleanroom and aerosol jet printing manufacturing methods for SAW microfluidic devices. Credit: Microsystems and nanoengineering
Surface acoustic wave (SAW) technologies, known for their high precision and rapid action, are essential to microfluidics and affect a broad spectrum of research areas. However, traditional manufacturing methods are time-consuming, complex, and require expensive clean rooms.
A new method overcomes these constraints by using aerosol jet printing to create customized devices with various materials, such as silver nanowires and graphene, significantly reducing development time.
In a study published in Microsystems and nanoengineering, researchers from Duke University and Virginia Tech have pioneered the integration of aerosol jet printing technology into the fabrication of SAW microfluidic devices. This advancement provides a faster, more versatile, cleanroom-free approach to developing lab-on-a-chip applications, revolutionizing fields from biology to medicine.
In this groundbreaking research, the team used aerosol jet printing to fabricate SAW microfluidic devices. This method stands in stark contrast to conventional, tedious cleanroom processes.
This involves depositing various conductive materials such as silver nanowires, graphene and poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) onto substrates to form interdigital transducers, essential for the generation of SAW for manipulating fluids and particles at the microscopic scale.
Remarkably, this method reduces manufacturing time from about 40 hours to about five minutes per device. The team analyzed the acoustic performance of these printed devices in depth using a laser Doppler vibrometer, comparing them to those manufactured in clean rooms.
The results showed promising potential, with the printed devices demonstrating similar or acceptable levels of performance in terms of resonance frequencies and displacement fields. This research represents a significant advance in the fabrication of microfluidic devices, providing a faster, more adaptable and more efficient alternative to traditional methods.
Dr Zhenhua Tian, co-author of the study, said: “This is not just a step forward; This is a leap into the future of microfluidic device manufacturing. Our method not only simplifies the process, but opens new possibilities for device fabrication. customization and rapid prototyping.
The implications of the new method are broad, providing a more accessible, faster and more cost-effective way to produce microfluidic devices. It has the potential to accelerate research and development in many areas, leading to faster diagnostics, improved drug delivery systems and improved biochemical analyses.
Additionally, the versatility of the technology suggests its adaptability to a wide range of materials and substrates, promising numerous applications in various disciplines.
More information:
Joseph Rich et al, Aerosol jet printing of surface acoustic wave microfluidic devices, Microsystems and nanoengineering (2024). DOI: 10.1038/s41378-023-00606-z
Provided by Aerospace Information Research Institute, Chinese Academy of Sciences
Quote: Aerosol jet printing could revolutionize the manufacturing of microfluidic devices (February 1, 2024) retrieved February 1, 2024 from
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