Rapid Prototyping of Tape-Based Microfluidic Chips With Versatile On-Chip Fluidic Functions

This paper presents a rapid prototyping method for fabricating double-sided tape-based microfluidic chips that address limitations in material flexibility, fabrication complexity, and on-chip functionalities. The approach employs biocompatible, low-cost materials—including medical-grade tapes, rubber, and thermoplastics (PMMA, polycarbonate, polystyrene)—micromachined via femtosecond lasers. Solvent- and heat-free tape-based bonding enables efficient fabrication of optically transparent, UV-sterilizable layers for biomedical applications. The method supports integrated on-chip pumps and active/passive valves, achieving bidirectional and multidirectional flow control with minimal external actuation. These components operate at up to 14 psi actuation pressure and $230~\mu $ L/min flow rates, adaptable via chamber dimensions. A dual-pump configuration mimics peristaltic pumping for continuous flow, while a prototype with multidirectional pumps and reservoirs demonstrates dynamic fluid routing and on-demand distribution. The technique offers a versatile, scalable solution for microfluidic applications requiring sterility, optical clarity, and on-chip fluidic control. [2025-0059]