A practical guide to rapid-prototyping of PDMS-based microfluidic devices: A tutorial

Micro total analytical systems (μTAS) are attractive to multiple fields that include chemistry, medicine and engineering due to their portability, low power usage, potential for automation, and low sample and reagent consumption, which in turn results in low waste generation. The development of fully-functional μTAS is an iterative process, based on the design, fabrication and testing of multiple prototype microdevices. Typically, microfabrication protocols require a week or more of highly-skilled personnel time in high-maintenance cleanroom facilities, which makes this iterative process cost-prohibitive in many locations worldwide. Rapid-prototyping tools, in conjunction with the use of polydimethylsiloxane (PDMS), enable rapid development of microfluidic structures at lower costs, circumventing these issues in conventional microfabrication techniques. Multiple rapid-prototyping methods to fabricate PDMS-based microfluidic devices have been demonstrated in literature since the advent of soft-lithography in 1998; each method has its unique advantages and drawbacks. Here, we present a tutorial discussing current rapid-prototyping techniques to fabricate PDMS-based microdevices, including soft-lithography, print-and-peel and scaffolding techniques, among other methods, specifically comparing resolution of the features, fabrication processes and associated costs for each technique. We also present thoughts and insights towards each step of the iterative microfabrication process, from design to testing, to improve the development of fully-functional PDMS-based microfluidic devices at faster rates and lower costs. [Display omitted] •An introduction in PDMS chemistry, surface modification and curing strategies is shown.•A critical evaluation of rapid-prototyping tools for PDMS-based microfluidic devices fabrication is made.•General strategies on the combination of fabrication tools and methods to meet users’ requirements are presented.•A comparison among microfabrication methods is made, in terms of feature resolution, cost and fabrication time.