Microfluidic technology is an emerging interdisciplinary field that uses micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, and biomedical engineering. As one of the rapid prototyping methods, the three-dimensional (3D) printing technique, which is rapid and cost-effective and has integrated molding characteristics, has become an important manufacturing technology for microfluidic chips. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presents a comprehensive process study on the fabrication of fused deposition modeling (FDM) 3D-printed PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D-printed integrated microfluidic reactors in the reaction between copper ions and ammonium hydroxide. In this work, a thermal stress finite element model shows that the printing platform temperature was a significant printing parameter to prevent warping and delamination in the 3D printing process. A single printing molding technique is employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experimental method of 3D-printed PMMA microchannels was carried out, and the optimized printing parameter resulted in a reduction in the microchannel profile to Ra 1.077 μm. Finally, a set of chemical reaction experiments of copper ions and ammonium hydroxide are performed in a 3D-printed microreactor. Furthermore, a color data graph of copper hydroxide is obtained. This study provides a cheap and high-quality research method for future research in water quality detection and chemical engineering.

This study systematically investigates the flow characteristics, mixing efficiency, and concentration gradient generation (CGG) capabilities of three types of vertical-stepped main-channel microfluidic concentration gradient generators—the upward vertical-step (UVS-GG), downward vertical-step (DVS-GG), and straight horizontal channel (SHC-GG)—under different Reynolds numbers (Re) through numerical simulation and comparative analysis. Using numerical simulations, the research reveals the universal transition of flow regimes from diffusion-dominated to convection-dominated and reports the emergence of a “multi-peak oscillatory concentration gradient” phenomenon under stepped geometries and high Re (Re = 100, 200). The results indicate that the SHC-GG can generate monotonic gradients at low Re, making it an ideal baseline configuration. In contrast, UVS-GG and DVS-GG enhance mixing and enable the programming of complex concentration distributions through unique inertia–geometry coupling effects. The synergistic interaction between geometric configuration and Re is identified as the core mechanism for regulating concentration field morphology and device performance. This study provides key theoretical and design foundations for the rational design of microfluidic gradient generators targeting applications such as biological screening, chemical analysis, and material synthesis.

Microfluidic technology is an emerging interdisciplinary field that use micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, microelectronics, new materials and biomedical engineering. As one of the rapid prototyping methods, three-dimensional (3D) printing technique with rapid and cost-effective and integrated molding characteristics has became one of the important manufacturing technologies of microfluidic chip. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presented a comprehensive process research on the fabrication of fused deposition modeling (FDM) 3D printing PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D printing integrated microfluidic reactors in the reaction between copper ions and ammonia water. In the work, the thermal stress finite element model shown the printing platform temperature was a significant printing parameters to prevent warping and delamination in the 3D printing process. And a single printing molding technique was employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experiment method of 3D printing PMMA microchannels was carried out, and the optimized printing parameters resulted in a reduction of the microchannel profile to Ra 1.077μm. Finally, a set of chemical reaction experiments of copper ions and ammonia water were performed in a 3D printed microreactor. And color datum graph of copper hydroxide were obtained. This works provided a cheap and high-quality research method for the future research in water quality detection and chemical engineering.

This study presents a high-efficiency CO ₂ laser micro-machining strategy for fabricating precision microfluidic architectures in polymethyl-methacrylate (PMMA) substrates, with a focus on establishing a predictive model for microchannel geometry. Through the systematic integration of finite element analysis (FEA) and experimental validation, the work investigates the thermomechanical interactions and geometric characteristics during CO ₂ laser machining of PMMA plates. The computational model is developed to simulate the evolution of the transient temperature field and predict distinct temperature regimes for single-pass and double-pass moving processes, reaching approximately 300 °C and 350 °C, respectively. Furthermore, the double-pass moving process exhibits a noticeable temperature superposition effect due to residual heat accumulation. Experimentally, the influence of laser power ranging from 8 to 13 W and moving speed varying from 5 to 30 mm/s on microchannel dimensions is systematically examined across 36 parameter sets. Each processing condition is replicated three times, with dimensional measurements taken at three distinct locations per microchannel, and the resulting standard deviations remain below 5 % of the mean values, confirming good reproducibility under consistent processing conditions. The results show microchannel width ranging from 150 ± 5 µm to 477 ± 15 µm and depth from 102 ± 5 µm to 3,266 ± 20 µm. Systematic analysis of the experimental cases reveals consistent trends whereby microchannel depth and width exhibit positive correlations with increasing laser power under constant moving speeds, while demonstrating inverse relationships with elevated moving velocities under fixed laser power conditions. The FEA simulations show strong agreement with experimental measurements, with microchannel width and depth prediction errors of less than 18 %. The key novelty of this work lies in the development of a high-fidelity, computationally efficient model that accurately predicts microchannel morphology by incorporating Gaussian energy distribution and thermal accumulation effects, validated across a wide range of practical processing parameters. This synergistic experimental-numerical approach provides a robust parametric optimization platform for laser-based microfabrication, significantly advancing the development of microfluidic systems through intelligent process design.