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Engineering Conferences InternationalECI Digital ArchivesSingle-use Technologies II: Bridging PolymerScience to Biotechnology Applications Proceedings
5-9-2017
Roll-to-Roll pilot line for large-scale manufacturingof microfluidic devicesMartin SmolkaJOANNEUM RESEARCH FmbH, Austria, [email protected]
Anja HaaseJOANNEUM RESEARCH FmbH, Austria
Ursula PalfingerJOANNEUM RESEARCH FmbH, Austria
Dieter NeesJOANNEUM RESEARCH FmbH, Austria
Ladislav KunaJOANNEUM RESEARCH FmbH, Austria
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Recommended CitationMartin Smolka, Anja Haase, Ursula Palfinger, Dieter Nees, Ladislav Kuna, Jan Hesse, Barbara Stadlober, Sascha. Geidel, Jörg Nestler,Nikolaus Ladenhauf, Andoni Rodriguez, Florian Hasenöhrl, Martin Eibelhuber, Max Sonnleitner, Guggi Kofod, Dan Kofoed, JanKafka, Isbaal Ramos, Manuel W. Thesen, Mirko Lohse, Ana Ayerdi, and Nerea Briz, "Roll-to-Roll pilot line for large-scalemanufacturing of microfluidic devices" in "Single-use Technologies II: Bridging Polymer Science to Biotechnology Applications", ktaMahajan (Genentech, Inc., USA) Gary Lye (University College London, UK) Regine Eibl-Schindler (Zurich University of AppliedScience, Switzerland) Eds, ECI Symposium Series, (2017). http://dc.engconfintl.org/biopoly_ii/51
AuthorsMartin Smolka, Anja Haase, Ursula Palfinger, Dieter Nees, Ladislav Kuna, Jan Hesse, Barbara Stadlober,Sascha. Geidel, Jörg Nestler, Nikolaus Ladenhauf, Andoni Rodriguez, Florian Hasenöhrl, Martin Eibelhuber,Max Sonnleitner, Guggi Kofod, Dan Kofoed, Jan Kafka, Isbaal Ramos, Manuel W. Thesen, Mirko Lohse, AnaAyerdi, and Nerea Briz
This abstract and presentation is available at ECI Digital Archives: http://dc.engconfintl.org/biopoly_ii/51
Roll-to-Roll Pilot Line for Large-Scale Manufacturing of Microfluidic Devices
European research project R2R Biofluidics
May 09, 2017
Single-Use Technologies II
Tomar, Portugal
Martin Smolka
Joanneum Research – Materials
Weiz (Austria)
Motivation
Production of microfluidic chips at lower price
than current technologies
Continuous production on large area
instead of batch process
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[prices of conventional
technologies taken from
Yole développement, 2012]
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flexible polymer
foil
UV-
resist
structured
and
cured resist
Roll-to-Roll (R2R) based Nano Imprint Lithography
Curing: T, UV
Working stamp
Imprint
Release
Substrate, resist
Highlights of Roll-to-Roll based Nano Imprint Lithography
Micropatterning on large area polymer rolls
Precise replication of micro- and nano structures
Functional materials (control of surface chemistry,
wettability, …)
Ease of prototyping
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M. Leitgeb,
D. Nees,
B. Stadlober
et al., ACS
Nano 10,
4926 (2016)
Depth 1100 nm
Width 200 nm
5 Roll-to-Roll (R2R) pilot line
R2R pilot line for microfluidic patterning
Coating Gravure printing Slot-die
Patterning R2R UV-imprinting R2R hot embossing
Max. web width 250 mm
Web speed 0.5 – 30 m/min
Laminar flow box ISO 7
Up to 3600 Chips per minute
(microscope slide format)
Roll-to-Roll (R2R) pilot line
Pilot line for UV Nano Imprint Lithography
Roll-to-Roll (R2R) pilot line
Assembly of foils to rigid substrates, Biflow systems (DE)
complex Single-Use devices
(„Lab-on-a-Chip“ systems, „smart“ Microtiter Plates)
From Nano to Macro: Master prototyping for R2R production
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„2 ½ D“ microfluidic structures by laser lithography
Flexible design of microfluidic channel network
precise small area mastering
50 µm 25 µm
From Nano to Macro: Master prototyping for R2R production
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50 µm
A) Mastering
B) Transfer to large area
master stamp?
?
From Nano to Macro: Master prototyping for R2R production
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Master replication in step and repeat imprint process
Small
scale
master
structure
Large area
R2R master
(„shim“)
UV-Lamp
Semi-transparent
mirror Alignment
Camera Movable
stamp
Substrate
Dispensing
system
Step & repeat system
EV Group E. Thallner
(AT)
Alternative approach:
Step-And-Repeat
Thermal Embossing
Inmold A/S (DK)
Fluidic channels / capillary pumps 11
Neuron Cell Culture Device
Roll-to-Roll production of
patterned surface with defined
cell adhesive areas
Seeding of neuronal cells
Formation of neural network
in defined microchannels
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Neuron Cell Culture Device
Implementation in microtiter
plate for parallel multi-
parameter cell studies
Application for fast drug
screening
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Neuron Cell Culture Device
Injection molding vs R2R nanoimprint?
Injection molding:
Big parts with high topography
R2R Nanoimprint:
Large area nano/micropatterns
simply combine the best of each technique
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Simulation and Mastering 15
Coating of channel walls with cell adhesive protein
Step 1: Fill channel networks with protein solution
► „open microfluidics“
Step 2: Evaporate solvent ► binding of proteins to surface
Computational Fluid Dynamics
(CFD) simulation of channel filling
by capillary forces
Selective coating of imprint structures with cell adhesive substrate (e.g. Poly-lysine, Laminin)
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50 µm
Large area imprints of neuron cell growth pattern 17
Summary
Roll-to-Roll Nano Imprint Lithography:
- Large scale production of microfluidic structures
- Future technology with low price per unit
Demonstrator 1:
In-vitro diagnostics chip with chemiluminescence detection
Demonstrator 2:
Cell culture plate for fast drug screening
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R2R Biofluidics Consortium
10 Partners - 4 European Countries
Innoprot S.L. (ES)
Tecnalia (ES)
InMold BioSystems A/S (DK)
BiFlow Systems (DE)
micro resist technology (DE)
bionic surface technologies (AT)
BioNanoNet (AT)
EV Group E. Thallner (AT)
Genspeed Biotech (AT)
Joanneum Research (AT)
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Acknowledgement 20
A. Haase, U. Palfinger, D. Nees, L. Lasave, L. Kuna, S. Jauck, M. Celikic, P. Tören, M. Smolka,
J. Hesse, S. Geidel, J. Nestler, N. Ladenhauf, F. Hasenöhrl, A. Rodriguez, M. Eibelhuber,
M. Sonnleitner, I. Katzmayr, M. Vogl, J. Kafka, D. Kofoed, G. Kofod, I. Ramos, M. Lohse,
M.W. Thesen, N. Briz, A. Ayerdi, G. Bijelic, S. Köstler and B. Stadlober
Thank you for your attention
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