Organ-on-Chip Molding Optimization: PDMS on SLA 3D-Printed Molds

Abstract

Organ-on-chip projects building miniature functional biological systems for disease research purposes benefit from reliable production of bioinert chambers to control the testing environment. To reliably mold such environments from PDMS style silicones such as SYLGARD™ 184, repeat attempts are often required when using an SLA 3D-printed mold: The material disturbs the cure. To reduce cost and offer higher yields of new prototypes without needing more chemically compatible mold materials such as CNC-machined aluminum, several known methods have been combined with new and tested experimental methods to offer enhanced yields with extremely small silicone parts. As a result of the project, consistent production of intact formations of the silicone molding has been increased from a modest 100° wall tapering at 600μm wall to wall width to an otherwise extremely difficult 90° at 400μm width, with abundant room for additional improvements using the methods described.