Continuous acoustic separation in a thermoplastic microchannel

Acoustic manipulation of particles and cells has been widely used for trapping and separation in microfluidic devices. Previously, the resonant components of these devices have been fabricated from silicon, glass, metals, or other materials having high acoustic impedance. Here, we present experimental results showing continuous acoustic focusing and separation of blood cells in a microchannel fabricated entirely from polystyrene. The efficiency and flow rates approach those reported in silicon and glass systems. We find that the optimum operating frequencies differ from those predicted by conventional approximations which have been developed for more rigid materials. Additionally, we introduce a method for fabrication of the devices, using an adaptation of thermofusion bonding that preserves critical channel dimensions. To control channel cross section during bonding, we introduced a collapsible fiberboard material in the bonding press. This structure provided a self-limiting force and mitigated deformation of the polystyrene. Together, these advances may enable new applications for acoustic focusing and separation in medical devices.