Abstract

This dissertation advances the field of microfluidic device fabrication through the development and application of high-resolution 3D printing technologies. The convergence of stereolithography (SLA) with digital light processing (DLP) has created unprecedented opportunities for microfluidic device fabrication, enabling truly three-dimensional structures with feature sizes approaching the single-micron scale. Building upon foundational work in custom 3D printer development, this research addresses critical limitations in 3D printing that have historically constrained microfluidic innovation, spanning multiple generations of custom 3D printers and technical innovations that have enabled the fabrication of increasingly complex microfluidic devices while enhancing resolution, repeatability, speed, and accessibility. A comprehensive review of 3D printing for organ-on-a-chip technologies contextualizes these technical advances, establishing the broader impact of high-resolution 3D printing on the field. The dissertation then presents several major innovations on microfluidic fabrication capabilities: first, a novel "zero-thickness layer" approach for fabricating biocompatible isoporous membranes with 7 micron pores integrated directly within devices, enabling features at the native resolution of the digital micromirror device; second, the development of Lattice, a Python-based software tool for position-specific exposure control that enables parallelized production of microfluidic devices while maintaining precise control over fabrication parameters and significantly reducing total print time through exposure optimization. Finally, contributions in 3D printed hydrophobic surface patterning, microfluidics integrated with optics and photonics, and the development of miniaturized pneumatic and one-way valves further demonstrate the versatility of these core technologies. These developments collectively advance high-resolution 3D printing for microfluidics, enabling faster prototyping, fabrication of more complex design geometries, higher repeatability, greater functional integration, and broader material compatibility than previously possible. The impact of this work is evidenced by its use in 30 publications across multiple research groups--a testament to the enabling nature of these technological advancements and their applicability to multidisciplinary research challenges.

Degree

PhD

College and Department

Ira A. Fulton College of Engineering; Electrical and Computer Engineering

Rights

https://lib.byu.edu/about/copyright/