Mastering Microfluidics: From Design to Mass Production
Microfluidics is transforming the way researchers and engineers approach diagnostics, drug delivery, environmental monitoring, microphysiological systems, and lab-on-a-chip systems. By controlling fluids at the microscale, microfluidic technologies enable faster, cheaper, and more precise experiments and devices.
But turning a microfluidic concept into a fully functional and mass-produced device is not straightforward. From design and simulation to mold creation, material selection, chip fabrication, and industrial scaling, the process can be overwhelming.
In this comprehensive guide, we’ll explore each step of the microfluidics workflow and how Eden Tech’s innovative tools, including FLUI’DEVICE, FLUI’MOLD, Epoxym, Flexdym, and Sublym, simplify the journey from idea to production.
1. Microfluidic Chip Design: Tools & Capabilities
Design is the foundation of any successful microfluidic project. High-quality microfluidic design software must enable layout creation, flow simulation, and seamless export for fabrication.
Software | Capabilities | Price Range | Simulation Engine | Notes |
AutoCAD + CFD | Layout + external simulation | ~$7,645/year | Add-on CFD | General-purpose CAD |
Multiphysics simulation + microfluidics | $4,000+/license | Built-in | Advanced, steep learning curve | |
SolidWorks + Flow | CAD + integrated fluid simulation | $3,995+/license | Flow Simulation module | Popular in industry |
Microfluidic CAD + flow calculations | Free – Premium | Built-in | Tailored for microfluidic design |
Why Choose FLUI’DEVICE?
FLUI’DEVICE is an intuitive, browser-based design platform tailored specifically for microfluidics. It includes built-in flow rate calculations, application-specific templates, and ready-to-export designs in formats like STL, SVG, and DXF. Whether you’re a beginner or an experienced engineer, FLUI’DEVICE makes microfluidic design fast and accessible.
Explore FLUI’DEVICE!
2. Microfluidic Mold Fabrication: From CAD to Master
After designing your chip, you need a mold to fabricate the device. Choosing the right mold material and provider affects resolution, durability, and cost.
Techniques | Resolution | Turnaround | Notes |
CNC | Hundred µm | Medium | Ideal for simple design |
Photolithography | High | Medium | Hard to achieve the advanced section & design |
DLP & SLA 3D Printing | ~100 µm | Medium | Ideal for simple design |
2PP | High | Variable | High-resolution & possibility to create advanced sections and structures |
Why FLUI’MOLD?
FLUI’MOLD offers high-resolution with fast turnaround and excellent dimensional accuracy using 2PP.
Learn more about FLUI’MOLD!
3. Mold Materials: Fragility vs. Flexibility
Your choice of mold material can make or break your workflow, literally.
Material | Resolution | Durability | Cleanroom Required | Notes |
SU-8 | High | Very Low | Yes | Fragile, cleanroom-only |
Silicon | Very High | Low | Yes | Brittle and expensive |
Metal | Medium | Very High | Sometimes | Expensive, long-lasting |
Epoxy | High | High | No | Easy in-lab mold replication |
Meet Epoxym: In-Lab Mold Replication Made Easy
Epoxym enables researchers to replicate microfluidic molds without a cleanroom. This biocompatible epoxy resin kit simplifies mold-making: just pour, cure, and reuse. Perfect for labs seeking flexibility and cost savings.
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4. Choosing the Right Microfluidic Chip Material
Material choice influences biocompatibility, optical clarity, bonding, and scalability. Here’s a quick comparison:
Material | Biocompatible | Optical Clarity | Scalability | Format | Notes |
PDMS | Yes | Excellent | Low | Liquid | Easy to prototype, hard to scale |
PMMA | Moderate | Good | Medium | Sheets | Brittle, bonding challenges |
COC/COP | Yes | Excellent | High | Pellets | Ideal for injection molding |
Glass | Yes | Excellent | Low | // | Fragile and costly |
Flexdym | Yes | Excellent | High | Sheets, Rolls, Pellets | Reusable, bondable, thermoplastic elastomer |
Flexdym: Bridging Prototyping and Production
Flexdym is an exclusive elastomer that combines the best of PDMS and thermoplastics. It’s biocompatible, does not adsorb small molecules, reusable, optically clear, and easy to prototype and assemble, making it the go-to material for any microfluidics application.
Get to know Flexdym!
5. Equipment: Making Microfluidic Chips Without a Cleanroom
Fabrication techniques vary based on resolution needs, material compatibility, and lab setup.
Material | Fabrication Techniques | Cleanroom Required | Pros |
PDMS | Soft lithography (with SU-8 molds) | Yes | – Easy to prototype – Flexible and transparent – Biocompatible |
Thermoplastics (e.g., PMMA, COC, COP) | Hot embossing, injection molding, CNC milling | No / Cleanroom optional | – Good scalability – Chemically resistant – Bonding options vary |
Glass | Wet/dry etching, powder blasting, bonding | Yes | – Excellent optical clarity – Chemically inert – Durable |
Flexdym | Hot embossing (e.g., with Sublym), roll-to-roll Injection molding Laser cutting | No | – Biocompatible – Reusable – Transparent – No cleanroom needed |
Sublym: Desktop Microfabrication Redefined
Sublym eliminates the need for expensive cleanrooms. This compact desktop unit supports both chip embossing and bonding, streamlining microfluidic prototyping in any lab environment.
Explore Sublym!
6. Scaling Microfluidic Production: From Lab to Factory
Scaling up means switching to durable molds, reproducible materials, and industrial-grade manufacturing techniques.
Material | Compatible Techniques | Scalability | Cost Efficiency |
PDMS | Soft lithography | Low | Low |
PMMA | CNC, hot embossing | Medium | Medium |
COC/COP | Injection molding, embossing | High | High |
Flexdym | Injection molding, Roll-to-roll, embossing | High | High |
Flexdym for Industry
With Flexdym available in pellet and roll formats, it’s ready for both small-batch and large-scale manufacturing. It enables a smooth transition from R&D to industrial production, with excellent reproducibility and performance.
Conclusion: Microfluidics From Design to Mass Production Made Simple
The road from concept to commercial microfluidic device is filled with challenges, but it doesn’t have to be. With the right tools and materials, you can design, prototype, and scale your microfluidic systems efficiently.
Eden Tech provides an integrated suite of microfluidic solutions:
- FLUI’DEVICE for design
- FLUI’MOLD and Epoxym for mold creation
- Flexdym for scalable material
- Sublym for on-site fabrication
Whether you’re an academic, startup, or industrial player, Eden Tech’s innovations help you master microfluidics at every stage.