Low-Cost, Rugged Microfluidics via Silver Clay Extrusion

We report novel, low-cost, high-temperature compatible, high-pressure compatible, and chemically resistant 3D printed microfluidics suitable for microreactors, heat exchangers, and other PowerMEMS applications. The devices are manufactured via silver clay extrusion; optimization of the printing method results in linearity between printed and computer-aided design (CAD) features, with ~11% (printed positive features, i.e. solid) and ~12% (printed negative features, i.e. voids) shrinking from CAD values after firing. Printed gaps as narrow as 200 μm were demonstrated, which are adequate to implement closed-channel microfluidics. A proof-of-concept microreactor that decomposes hydrogen peroxide was designed, fabricated, and characterized, demonstrating 86% efficiency with initial 30% hydrogen peroxide (w/w) in water concentration.