Paper meets polymer: Efficiently manufacturing hybrid microfluidics for membrane-based applications
Journal
Chemical Engineering Journal
Series/Report No.
Chemical Engineering Journal
Journal Volume
522
Start Page
Article number 167788
ISSN
1385-8947
Date Issued
2025-10
Author(s)
Abstract
Hybrid microfluidic platforms combining paper and polymer substrates hold great potential for chemical and biomedical applications but often face challenges like leakage and limited functionality due to weak integration methods. This study introduces a two-step fabrication process to create compact, one-piece hybrid paper/polymer (OHPP) microfluidic devices with enhanced bonding strength, reaching up to 720 kPa, and long-term stability. The process ensures direct, leak-free bonding between substrates, enabling the paper membrane to function not only as a passive but also as an active fluidic component. Using digital light processing (DLP), we fabricated porous paper membranes with patternable hydrophilic and hydrophobic zones for advanced fluid control. We demonstrated three key applications, including (1) a passive micromixer where the cellulose fiber network induces chaotic advection and initiates mixing action, (2) a concentration gradient generator where different paper patterns and flow rates precisely controlled the gradient profile, and (3) a two-phase oil/water separator where paper membranes with stripe pattern achieved over 80 % recovery and 100 % purity by using capillary action and interfacial tension. The devices operate reliably at flow rates up to 60 μL/min and maintain stable performance over time. This fabrication method provides a low-cost, scalable, and customizable solution for hybrid microfluidic devices, enhancing the role of paper membranes in complex fluidic processes.
SDGs
Publisher
Elsevier BV
Type
journal article