Microfabrication
Author
Camila Betterelli Giuliano, PhD
Publication Date
February 27, 2025
Keywords
Intelligent Microfluidics
Deep Learning
Microfluidic Devices
Artificial Intelligence
Machine Learning
Microfabrication
Thermoplastics
3D printing
Chip prototyping
Biocompatible printing
Your microfluidic SME partner for Horizon Europe!
When people think about microfluidics, what comes to mind is usually the microfluidic chip. It makes sense because the magic happens inside the chip.
At the MIC, our main focus is on the instruments that go around the chip, i.e., the pumps, valves, sensors, etc. But none of this would make sense without the microfluidic chip. Thus, we cannot overlook the challenges researchers face when microfabricating their microfluidic devices.
PDMS microfabrication has democratised the access to microfluidics in many labs around the world, but, as the field advances, its limitations become more apparent. Thermoplastics came forth as a valuable substitute but their microfabrication is either too expensive or too difficult.
BioProS, easy chip prototyping with thermoplastics
As part of the project BioProS, the MIC aims to address precisely these limitations by creating a process of thermoplastic chip microfabrication analogous to the one in PDMS (GA no. 101070120).
We used our expertise in fabricating PDMS chips without the need for a cleanroom and translated it to PMMA. The result is an effective protocol for fast and easy thermoplastic chip prototyping.
If you want to know more about the project or about the protocol, just follow the links!
Examples of PMMA chips
3D printing of customized flow cells
Different applications have different needs and, in some special cases, we 3D print custom-made flow cells to fulfill the needs of our projects. We have several printing methods in-house, including a biocompatible printer and resin.
For example, for the project Panbiora, we designed and 3D-printed a microfluidics chip to adapt AMES tests, widely used genotoxicity tests, to microfluidics (GA no. 760921).
The test performed on our designed chip achieved a decrease by half of the testing time and required significantly less material and space.
If you want more info, the results are published here:
Varvara Gribova, Jesus Manuel Antunez Dominguez, Alan Morin, Julia Sepulveda Diaz, Philippe Lavalle, et al.. A miniaturized genotoxicity evaluation system for fast biomaterial-related risk assessment. Analytical Methods, 2023, 15 (12), pp.1584-1593.
https://hal.science/hal-04054693v1/file/islandora_161296.pdf
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FAQ – Microfabrication
What materials do you use for microfabrication?
- PDMS: Common and easy for proofs of concept.
- Thermoplastics (PMMA, COC/COP, PS, etc.): Better for robustness, chemical resistance, and scalability.
- Glass and silicon: For harsh chemical environments, high temperatures, or when you need highly precise features.
We always choose the material based on the application’s needs, including optical clarity, gas permeability, chemical resistance, solvent compatibility, and cost.
What fabrication processes are on the menu?
Photolithography and soft lithography for PDMS; CNC micromilling and laser ablation for rapid thermoplastic chips; hot embossing and solvent/thermal bonding for clean channel replication; wet/dry etching for glass/silicon when you need sub-100 µm accuracy and robust surfaces. We also do thin-film surface treatments, plasma activation, and selective coating for wettability control or biomolecule coupling.
Do you prototype thermoplastic chips easily?
What about 3D printing in microfluidics?
We also use 3D printing (including biocompatible resins) to create custom flow modules or chip holders when standard layouts don’t fit. These printed pieces can complement or even replace parts of conventional chips.
What about surface chemistry and biocompatibility?
We can render channels hydrophilic/hydrophobic, graft PEG-like anti-fouling layers, or prepare surfaces for antibody/ECM attachment. For cell work, we keep an eye on extractables and use bonds and solvents with good biocompatibility track records. If your assay is sensitive, we’ll recommend validation steps (contact angle, burst tests, cytotoxicity) early.
Why move away from PDMS toward thermoplastics?
PDMS is great for early-stage experiments, but it has limitations (e.g. absorption of certain molecules, limited chemical compatibility). Thermoplastics offer better mechanical and chemical properties for many real-world uses.
What information should I send to get a quote or a quick feasibility check?
A sketch or CAD (even rough), expected flow rates/pressures, fluids/solvents, temperature range, assay constraints (cells, enzymes, organic solvents), optical needs, and desired batch size. If you already ran benchtop tests, share the data and pain points – you’ll get a sharper proposal.
What is the Microfluidics Innovation Center (MIC)?
The Microfluidics Innovation Center, or MIC, is a small to medium-sized enterprise (SME) company based in Paris. It was created in 2011 by researchers from Elvesys. We focus on building custom microfluidic systems and have participated in over 50 European and national research projects. Some of our work has even helped launch 10 spin-off startups.
PS: We are not a consulting firm! Like all project partners, we are only funded if the proposal is selected by the European Commission, and only for the R&D work packages we deliver.
How does MIC fit into a Horizon Europe consortium?
We typically handle engineering and system validation, allowing academic partners to focus on their scientific work.
Reviewers also appreciate when a project includes a small/medium enterprise (SME) with hands-on experience.
In fact, our involvement often doubles proposal success rates, because we directly address risk and manufacturability, key evaluation factors.
What services can the MIC provide to a consortium?
We contribute to the technical, innovation, and impact sections of the proposal, suggest partners when relevant, and develop microfluidic technologies. We also support activities linked to market potential and impact.
