Roll-to-Roll Manufacturing of Integrated Immunodetection Sensors.

Lack of functional integration and high manufacturing costs have been identified as major challenges in commercialization of point-of-care devices. In this study, roll-to-roll (R2R) fabrication process was developed for large-scale manufacturing of disposable microfluidic devices. The integrated, user-friendly device included a plasma separation membrane for simple blood filtration, immobilized antibodies for specific immunodetection, microfluidics for plasma transport and reagent mixing, and a blister for actuation and waste storage.

A disposable, roll-to-roll hot-embossed inertial microfluidic device for size-based sorting of microbeads and cells.

Inertial microfluidics has been a highly active area of research in recent years for high-throughput focusing and sorting of synthetic and biological microparticles. However, existing inertial microfluidic devices always rely on microchannels with high-aspect-ratio geometries (channel width w < channel height h) and small cross-sections (w×h < 50 × 100 μm(2)). Such deep and small structures increase fabrication difficulty and can limit manufacturing by large-scale and high-throughput production approaches such as roll-to-roll (R2R) hot embossing.

Reduced Blood Coagulation on Roll-to-Roll, Shrink-Induced Superhydrophobic Plastics.

The unique antiwetting properties of superhydrophobic (SH) surfaces prevent the adhesion of water and bodily fluids, including blood, urine, and saliva. While typical manufacturable approaches to create SH surfaces rely on chemical and structural modifications, such approaches are expensive, require postprocessing, and are often not biocompatible. By contrast, it is demonstrated that purely structural SH features are easily formed using high throughput roll-to-roll (R2R) manufacturing by shrinking a prestressed thermoplastic with a thin, stiff layer of silver and calcium.

Disposable roll-to-roll hot embossed electrophoresis chip for detection of antibiotic resistance gene mecA in bacteria.

We present a high-throughput roll-to-roll (R2R) manufacturing process for foil-based polymethyl methacrylate (PMMA) chips of excellent optical quality. These disposable, R2R hot embossed microfluidic chips are used for the identification of the antibiotic resistance gene mecA in Staphylococcus epidermidis. R2R hot embossing is an emerging manufacturing technology for polymer microfluidic devices.