Reusable, adhesiveless and arrayed in-plane microfluidic interconnects

A reusable, arrayed interconnect capable of providing multiple simultaneous connections to and from a microfluidic device in an in-plane manner without the use of adhesives is presented. This method uses a ‘pin-and-socket’ design in which an SU-8 anchor houses multiple polydimethysiloxane septa (the socket) that each receive a syringe needle (the pin). A needle array containing multiple commercially available 33G (203 μm outer diameter) needles (up to eight) spaced either 2.54 or 1 mm (center-to-center) pierces the septa to access the microfluidic device interior. Finite element modeling and photoelastic stress experiments were used to determine the stress distribution during needle insertion; these results guided the SU-8 septa housing and septa design. The impact of needle diameter, needle tip style, insertion rate and number of needles on pre-puncture, post-puncture and removal forces was characterized. Pressurized connections to SU-8 channel systems withstood up to 62 kPa of pressurized water and maintained 25 kPa of pressurized water for over 24 h. The successful integration and functionality of the interconnect design with surface micromachined Parylene C microchannels was verified using Rhodamine B dye. Dual septa systems to access a single microchannel were demonstrated. Arrayed interconnects were compatible with integrated microfluidic systems featuring electrochemical sensors and actuators. (Some figures in this article are in colour only in the electronic version)