| dc.description.abstract | This study introduces a novel approach to tissue-on-chip device fabrication using low-cost picosecond laser ablation, addressing critical limitations in current manufacturing methods such as soft lithography, particularly in terms of material compatibility, feature resolution, and scalability. We developed a comprehensive finite element method (FEM) model for the laser ablation process, incorporating key physical phenomena including laser-material interactions, heat transfer, and material removal dynamics. This model, validated against experimental results, accurately predicts ablation depths within 20% of measured values across a range of laser parameters. Our experimental setup, utilizing a cost-effective 10 kHz picosecond laser system, demonstrates superior capabilities in creating high-aspect-ratio microchannels exceeding 20:1, surpassing traditional manufacturing techniques. We achieve precise control over channel dimensions, with widths ranging from 20 to 500 micrometers and depths up to 1 mm, while maintaining sub-micron surface roughness (Ra < 0.8 𝜇m). The system’s versatility is showcased through the fabrication of complex structures such as Tesla valves and high-resolution text features, with a minimum feature size of 20 𝜇m. We present practical techniques for component selection and process parameter optimization 3 using our simulation, reducing expensive and time-consuming experimentation. This work establishes low-cost picosecond laser ablation as a viable and advantageous method for tissue-on-chip manufacturing. With fabrication times of 6-8 minutes for small features and less than an hour for a full chip, our method represents a significant advancement in rapid prototyping capabilities. These findings demonstrate that laser ablation is a powerful technique for manufacturing tissueon-chip devices, offering high resolution, flexibility, and scalability. This approach has the potential to overcome the limitations of traditional methods, enabling the next generation of sophisticated, physiologically relevant in vitro models for biomedical research and drug development. The successful development and validation of the FEM model, coupled with practical demonstrations, provide a solid foundation for further advancements in laser-based fabrication of tissue-on-chip devices, potentially accelerating drug discovery processes and enabling more accessible production of personalized medicine platforms. | |
