Negative features in microdevices find a wide range of applications. The process of 3D printing has revolutionized their fabrication due to the combination of good resolution and integration capability. Herein, we report on a systematic study of the effects of materials and print directions on the 3D printing of microfluidic channels as negative features under PolyJet technology. Specifically, the Statasys Objet500 printer was used for this study. We printed two sets of chips (n=10 each), each of which contains channel pairs of a high-contrast reference material and a sacrificial material, respectively. Both materials were embedded in a clear photopolymer resin. The channel pairs ranged in planned width from 64 to 992 μm. To explore the effect on print orientation, channels were printed either parallel or perpendicular with respect to the jetting head's movement. The width of each channel of a pair was compared for each planned width and each combination of materials. The effect of print orientation on channel morphology was also investigated. We found that reproducibility and accuracy were highest at a planned channel width of approximately ≥600 μm and that channel morphology was most suitable when the jetting head of the printer moved parallel to the channel's longitudinal axis. The results should be of interest to any users who wish to create negative features using PolyJet 3D technology.
Keywords: 3D printing; accuracy; additive manufacturing; embedded; fidelity; photopolymers; precision; prototyping; sacrificial material.