roll-to-roll pilot line for large-scale manufacturing of

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, martin.smolka@joanneum.at

Anja HaaseJOANNEUM RESEARCH FmbH, Austria

Ursula PalfingerJOANNEUM RESEARCH FmbH, Austria

Dieter NeesJOANNEUM RESEARCH FmbH, Austria

Ladislav KunaJOANNEUM RESEARCH FmbH, Austria

See next page for additional authors

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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

2

[prices of conventional

technologies taken from

Yole développement, 2012]

3

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

4

4

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

9

50 µm

A) Mastering

B) Transfer to large area

master stamp?

?

From Nano to Macro: Master prototyping for R2R production

10

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

12

Neuron Cell Culture Device

Implementation in microtiter

plate for parallel multi-

parameter cell studies

Application for fast drug

screening

13

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

14

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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