Rapid prototyping of microfluidics devices using novel thermoset polydicyclopentadiene

This study demonstrates the facile fabrication of microfluidic devices using novel thermoset polydicyclopentadiene (PDCPD). The fabrication process was accomplished using a strategy similar to soft lithography using polydimethylsiloxane (PDMS). The semi-cured PDCPD gel prepared from the thermal latent system of dicyclopentadiene retained the advantage of rapid and easy assembly via conformal contact, which is commonly achieved for devices fabricated from PDMS. Two methods were developed to form permanent bonding between PDCPD and PDMS, glass, and PDCPD, based on the polymerization of the semi-cured gel. The solvent compatibility of PDCPD was tested using various solvents over a period of 24 h, revealing excellent tolerance to acids, bases, alcohols, acetonitrile, ethyl acetate, and aliphatic hydrocarbons. However, PDCPD exhibited a low tolerance toward aromatic hydrocarbons, tetrahydrofuran, and chlorinated solvents. PDCPD devices demonstrated approximately 90% and 86% transmittance for 1 and 4 mm thick samples, respectively, in the visible-light region (400-800 nm). To further demonstrate the versatility of the material, droplets were generated on a PDCPD microfluidic device. This study confirmed the feasibility of using PDCPD as a routine material for the rapid prototyping of new designs.