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Biomicrofluidics. 2013 Sep 11;7(5):56501. doi: 10.1063/1.4821315. eCollection 2013.

Manufacturing and wetting low-cost microfluidic cell separation devices.

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  • 1Department Mechanical and Manufacturing Engineering, University of New South Wales, New South Wales 2052, Australia.
  • 2Department of Engineering, Macquarie University, New South Wales 2109, Australia.


Deterministic lateral displacement (DLD) is a microfluidic size-based particle separation or filter technology with applications in cell separation and enrichment. Currently, there are no cost-effective manufacturing methods for this promising microfluidic technology. In this fabrication paper, however, we develop a simple, yet robust protocol for thermoplastic DLD devices using regulatory-approved materials and biocompatible methods. The final standalone device allowed for volumetric flow rates of 660 μl min(-1) while reducing the manufacturing time to <1 h. Optical profilometry and image analysis were employed to assess manufacturing accuracy and precision; the average replicated post height was 0.48% less than the average post height on the master mold and the average replicated array pitch was 1.1% less than the original design with replicated posts heights of 62.1 ± 5.1 μm (mean ± 6 standard deviations) and replicated array pitches of 35.6 ± 0.31 μm.

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