Applications of stereolithography for rapid prototyping of biologically compatible chip-based physiometers

Despite the growing demand and numerous applications for the biomedical community, the developments in millifluidic devices for small model organisms are limited compared to other fields of biomicrofluidics. The main reasons for this stagnanation are difficulties in prototyping of millimeter scale and high aspect ratio devices needed for large metazoan organisms. Standard photolithography is in this context a time consuming procedure not easily adapted for fabrication of molds with vertical dimensions above 1 mm. Moreover, photolithography is still largely unattainable to a gross majority of biomedical laboratories willing to pursue custom development of their own chip-based platforms due to costs and need for dedicated clean room facilities. In this work, we present application of high-definition additive manufacturing systems for fabrication of 3D printed moulds used in soft lithography. Combination of 3D printing with PDMS replica molding appears to be an alternative for millifluidic systems that yields rapid and cost effective prototyping pipeline. We investigated the important aspects on both 3D printed moulds and PDMS replicas such as geometric accuracies and surface topology. Our results demonstrated that SLA technologies could be applied for rapid and accurate fabrication of millifluidic devices for trapping of millimetre-sized specimens such as living zebrafish larvae. We applied the new manufacturing method in a proof-of-concept prototype device capable of trapping and immobilizing living zebrafish larvae for recording heart rate variation in cardio-toxicity experiments.