Researchers at the University of Maine, working with Sappi North America, have developed a low-cost method to produce microdroplet generators using scalable manufacturing techniques adapted from the paper industry.
Microdroplet generators are used in drug testing, cosmetics and cell analysis. Traditional production relies on clean rooms, laser ablation and specialised equipment. Costs are high.
The team set out to simplify the process. By using Sappi’s industrial capabilities, they designed micro-scale channel patterns that can be produced at high speed and low cost.
Sappi applied its expertise in precision patterning to create channels at the micron scale. These patterns are stamped into substrates using methods compatible with mass production. The result is a simpler process that avoids several complex fabrication steps.
According to the researchers, the approach allows hundreds of thousands of units to be produced per hour.
The device is designed for repeated use. It can be assembled and disassembled for cleaning. Its structure combines polycarbonate and high-hardness silicone layers to prevent leaks and maintain stability during operation.
To test performance, the team used agar to simulate blockages and evaluate droplet formation. The device remained functional after cleaning and reassembly.
The project shows how paper-based manufacturing techniques can be applied beyond traditional products. The ability to produce precise microstructures at scale opens new paths for fibre-based processes in biotechnology and diagnostics.
The work was supported by several research programs, including the National Science Foundation and the National Institutes of Health.
Sappi North America is a producer of paper, packaging and pulp, with manufacturing operations across the United States and Canada. The company develops fibre-based materials and applies its manufacturing expertise to a range of industrial and technical applications.
The University of Maine is a public research university and a member of the U.S. R1 category, focused on advanced research and industry collaboration. It conducts work across engineering, forest products and materials science, often in partnership with industrial stakeholders.
Source: UMaine
