Print-Aware Synthesis and Physical Design Methodologies for 3D-Printed Microfluidic Biochips

📅 2026-08-17
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🤖 AI Summary
This study addresses the challenges of complex design and low fabrication precision caused by material over-curing in 3D-printed microfluidic chips. We propose a manufacturing-oriented automated design framework that integrates interactive CAD, perception-aware automatic synthesis algorithms, and print compensation strategies to achieve end-to-end automation from functional synthesis to manufacturing optimization. This approach effectively overcomes fidelity bottlenecks inherent in low-cost resin printing, significantly improving channel patency and device functionality. By lowering design barriers and enhancing fabrication reliability, the proposed method accelerates the prototyping iteration cycle for microfluidic devices, facilitating more accessible and efficient development of lab-on-a-chip systems.
📝 Abstract
Microfluidic devices are widely used in diagnostics, chemical synthesis, and biological analysis, but their development often depends on complex fabrication and design processes. Resin-based three-dimensional (3D) printing has emerged as a promising alternative to conventional microfabrication because it enables low-cost, rapid prototyping of complex multi-layer structures. However, the practical realization of 3D-printed microfluidic biochips remains challenging due to manual and expertise-intensive design workflows, the rigid nature of commonly used printing materials, and fabrication inaccuracies such as over-curing that distort internal features and may block narrow channels. In this paper, we present a cohesive design automation framework for 3D-printed microfluidics that addresses these challenges across both device design and fabrication. The framework combines interactive design tools, automated synthesis methods for functional 3D microfluidic devices, techniques for developing low-cost 3D-printed mixers, and design-for-manufacturing strategies to improve print fidelity on low-cost resin printers.
Problem

Research questions and friction points this paper is trying to address.

3D-printed microfluidics
design automation
fabrication inaccuracies
over-curing
biochips
Innovation

Methods, ideas, or system contributions that make the work stand out.

Design Automation
3D-Printed Microfluidics
Design-for-Manufacturing
Print-Aware Synthesis
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