Fabrication of 3D PDMS Microchannels of Adjustable Cross-Sections via Versatile Gel Templates

Flexible gel fibers with high stretchability were synthesized from physically cross-linked agar and covalently cross-linked polyacrylamide networks. Such gel material can withstand the temperature required for thermal curing of polydimethylsiloxane (PDMS), when the water in the gel was partially replaced with ethylene glycol. This gel template supported thermal replica molding of PDMS to produce high quality microchannels. Microchannels with different cross sections and representative 3D structures, including bifurcating junction, helical and weave networks, were smoothly fabricated, based on the versatile manipulation of gel templates. This gel material was confirmed as a flexible and reliable template in fabricating 3D microfluidic channels for potential devices.