Simple and low-cost fabrication of PDMS microfluidic round channels by surface-wetting parameters optimization

Convenient for both biologists and MEMS designers, Polydimethylsiloxane (PDMS) polymer is intensively investigated for its biocompatibility, transparency, high resistance under plasma treatment, flexibility and resistance to high temperature. However, for microfluidic applications, the fabrication of PDMS circular channels is difficult to achieve except by wire moulding. In this article, we present a simple, fast and low-cost fabrication method which can be applied out of clean-room environment. It is based on the deposition of alginic acid sodium salt aqueous solution, enabling the formation of a liquid cylinder on the most hydrophilic part of a hydrophilic/hydrophobic patterned surface. We experimentally studied the interaction between liquid rivulets and surfaces presenting a contrast of wettability and/or a stepwise texture. Subsequent moulding of the half-cylinder of liquid produces round PDMS microfluidic channels. The optimal parameters for hydrophilic/hydrophobic patterns have then been applied to produce the roundest possible channels. The realisation of both straight channels 300–500 μm wide, 1 cm long and 75° tangent chord angle at best, and Y-shaped channels with the same dimensions and 55° TCA is demonstrated.