We provide a facile and low-cost method (F-L) to fabricate a two-dimensional positive master using a milling technique for polydimethylsiloxane (PDMS)-based microchannel molding. This method comprises the following steps: (1) a positive microscale master of the geometry is milled on to an acrylic block; (2) pre-cured PDMS is used to mold the microscale positive master; (3) the PDMS plate is peeled off from the master and punctured with a blunt needle; and (4) the PDMS plate is O₂ plasma bonded to a glass slide. Using this technique, we can fabricate microchannels with very simple protocols quickly and inexpensively. This method also avoids breakage of the end mill (ϕ = 0.4 mm) of the computerized numerical control (CNC) system when fabricating the narrow channels (width < 50 µm). The prominent surface roughness of the milled bottom-layer could be overcomed by pre-cured PDMS with size trade-off in design. Finally, emulsion formation successfully demonstrates the validity of the proposed fabrication protocol. This work represents an important step toward the use of a milling technique for PDMS-based microfabrication.

Fabrication of small diameter vascular grafts (SDVGs) with appropriate responses for clinical application is still challenging. In the present work, the production and characterization of solid alginate based microfibers as potential SDVG candidates through the method of microfluidics were considered original. A simple glass microfluidic device with a ‘L-shape’ cylindrical-flow channel in the microfluidic platform was developed. The gelation of microfibers occurred when the alginate solution and a CaCl ₂ solution were introduced as a core flow and as a sheath flow, respectively. The diameters of the microfibers could be controlled by varying the flow rates and the glass capillary tubes diameters at their tips. The generated microfibers had somewhat rough and porous surfaces, their suture retention strengths were comparable to the strength of other tissue engineered grafts. The encapsulated mesenchymal stem cells proliferated well in the microfibers, and showed a stable endothelialization under the angiogenesis effects of vascular endothelial growth factor and fibroblastic growth factor. The in vivo implant into the mice abdomens indicated that cell composite microfibers caused a mild host reaction. These encouraging results suggest great promise of the application of microfluidics as a future alternative in SDVGs engineering.

This paper describes a highly controllable method to generate hollow calcium alginate microfibers using a double co-axial flow microdevice. The microdevice was fabricated by concentric assembly of two modules; each module consisted of a shortened cone-pulled glass capillary embedded in a polymethylmethacrylate fluidic block. Using this microdevice, cylindrical hollow calcium alginate microfibers with either straight or helical inner walls were stably and continuously generated. The radii of the hollow microfibers were not arbitrary, and in fact, the ratio of the outer to inner diameter was inversely correlated with the combination of core flow rate and the first sheath flow rate. The relationships between the geometrical features of the helix and the flow rates were also analyzed. The helical pitch and the spiral radius of the helical hollow microfibers were strongly influenced by the second sheath flow rate. Finally, guidelines for generating highly controllable straight and helical hollow microfibers and fabricating a seamless flow connector using this microfluidic device are suggested.