Matheus J. T. Vargas*abc,
Michel K. Nieuwoudtbc,
Rakesh Arulbe,
David E. Williamsac and
M. Cather Simpsonabd
aOrbis Diagnostics Ltd, 14 West Street, Eden Terrace, Auckland, 1010, New Zealand. E-mail: matheus@orbisdiagnostics.com; david.williams@auckland.ac.nz; c.simpson@auckland.ac.nz
bPhoton Factory, University of Auckland, 38 Princes St, Auckland, 1010, New Zealand
cSchool of Chemical Sciences, University of Auckland, Bldg. 302, 23 Symonds St, Auckland 1010, New Zealand
dDepartment of Physics, University of Auckland, 38 Princes Street, Auckland, 1010, New Zealand
eCavendish Laboratory, Department of Physics, University of Cambridge, JJ Thompson Avenue Cambridge, CB3 0HE, UK
First published on 25th July 2023
In this study, we utilize nanosecond and femtosecond direct laser writing for the generation of hydrophobic and hydrophilic microfluidic valves on a centrifugal microfluidic disk made of polycarbonate, without the need for wet-chemistry. Application of a femtosecond (fs) laser at 800 nm resulted in an increased contact angle, from ∼80° to ∼160°, thereby inducing the formation of a hydrophobic surface. In contrast, employing a nanosecond (ns) laser at 248 nm led to the formation of superhydrophilic surfaces. Morphological studies identified the enhancement in the surface roughness for the hydrophobic surfaces and the creation of smooth patterns for the hydrophilic surfaces. Chemical modifications in the laser-ablated samples were confirmed via Fourier-transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS) analysis. These spectroscopic examinations revealed an increase of hydrophilic chemical groups on both surfaces, with a more pronounced increase on the nanosecond laser-modified surface. Furthermore, these surfaces were used as a case study for centrifugal microfluidic valves. These modified surfaces demonstrated peculiar pressure responses. Specifically, the hydrophobic valves necessitated a 29% increase in pressure for droplet passage through a microchannel. On the other hand, the superhydrophilic valves exhibited enhanced wettability, decreasing the pressure requirement for fluid flow through the modified area by 39%. However, similarly to the hydrophobic valves, the fluid exiting the hydrophilic valve area required an increased pressure. Overall, our study shows the potential for tailoring valve functionality in microfluidic systems through precise surface modifications using laser technology.
The selection of an appropriate polymer substrate for a microfluidic device relies heavily on its physicochemical characteristics. Some of PC's characteristics, high chemical stability, poor surface absorbability and adhesion to other films and coatings (great for bioassay microchips), make this polymer a candidate to be integrated into μTAS devices.7–10 However, these characteristics carry some challenges when dealing with microfluidics, where many times it is necessary to fine tune its properties for better fluidic control. Several studies have tried to tune the PC's dielectric properties,11 create surface modifications (and wettability)7 on devices, study the effect of chemical modification using laser ablation12 and even ways to construct micropatterning13 on surfaces. These current strategies to modify bare polymer surfaces mainly include chemical14 and plasma15 treatments, but direct laser surface modification is emerging as a more flexible technique due to its ability to perform surface patterning at high precision.
In order to reduce chemical waste and achieve greater reproducibility and precision in surface modifications for the creation of hydrophobic surfaces, researchers have explored the use of femtosecond pulsed laser irradiation. This technique has been seen in various applications, including micro hole drilling, micro patterning, and lens arrays16–18 as well as on polycarbonate surfaces.19 Furthermore, the use of different lasers, such as UV lasers applied on polymers, to create hydrophilic surfaces are quite scarce as most studies focus on chemical treatments or plasma treatments that lead to less control of the modified surface area.20–22 Currently, there are no detailed studies on directly application of femtosecond nor nanosecond laser modifications to thermoplastic microfluidic devices. Especially in systems that do not use actuated pumps to control fluids, (e.g. paper microfluidics,23 centrifugal microfluidics,24,25 suspended microfluidics,26 and digital microfluidics27), hydrophilic and hydrophobic circuit sections become elegant tools to control fluid flow via capillary forces, adhesion, and hydrophobicity.
In this study, we present techniques to modify the surface properties of polycarbonate, specifically Makrofol DE 1-1, in specific regions of a centrifugal microfluidic device. By employing femtosecond and nanosecond laser pulses at different wavelengths, we can precisely transform designated areas into either hydrophobic or hydrophilic surfaces. This capability allows for fine-tuning the fluid flow within different sections of the same device, all using the same material.
Femtosecond laser ablation of polymeric materials at 800 nm (1.55 eV) occurs through a different mechanism compared to the longer-pulse nanosecond laser. With femtosecond irradiation at 800 nm, the near-infrared photons are nonlinearly absorbed through multiphoton absorption.34 This type of absorption at femtosecond time scale generates energy that is sufficient to enable laser processing at wavelengths at which the material is non-absorbent or transparent. For example, near-infrared wavelengths can be used to ablate polymers that are non-absorbent at the used laser wavelength.35 Multiphoton absorption is thought to be followed by avalanche mechanisms, leading to photodegradation of materials.36 Femtosecond pulsed lasers thus can induce non-thermal37 structural and morphological changes in the ablated material, avoiding mostly of the material oxidation when ablated in open air. In addition, the use of femtosecond lasers can induce the formation of periodic structures or high roughness in polymers, which are well-known to generate efficient hydrophobic surfaces.38–40
The burst frequency in centrifugal microfluidics is dependent on the pressure the fluid exerts in the channel. The main factors controlling this pressure when a centrifugal disk is in stationary position are the dimensions of the channels, given by width (w) and height (h), the contact angles on the walls corresponding to the width and height, respectively, θw related to the top and bottom of the channels and θh corresponding to the side walls of the channel, and the surface tension of the liquid (σ). eqn (1) gives the pressure change across the meniscus.
(1) |
Since we are working with a centrifugal microfluidic device for this study, we can use an equation to estimate the pressure (Pω) related to the centrifugal force (Fc) during disk rotation:
Fc = ρω2R | (2) |
(3) |
As the disk spins and the fluid encounters a capillary, hydrophobic or hydrophilic section it needs more force to pass these barriers. A centrifugal force-actuated valve is open when Pω is higher than the Pcap. The frequency or rotational speed at which the valve is opened has been reported by is given by different groups, including Lu et al., Ouyang et al., and Madou et al.41,43 Eqn (4) shows the burst frequency fo in revolutions per minute (RPM) based on their studies:
(4) |
The burst pressure to overcome the capillary force, using angular speed in RPM units is:
(5) |
By employing appropriate equations, we can identify the effectiveness of hydrophobic or hydrophilic modifications in a microchannel holding a fluid.
Hydrophobic PC surfaces were fabricated with femtosecond laser irradiation (800 nm, 100 fs pulse duration, 1 kHz, Legend Elite, Coherent Inc., USA) using the same machining stage as the nanosecond laser system and a square mask. The optimized femtosecond laser settings used were 2500 μm2 square spot sizes (50 μm × 50 μm, square shaped); 1 μm spacing between shots and 40, 45, 50, 55 μm spacing between lines and powers of 5 and 13 mW. The total surface area machined using both laser systems was 6 × 6 mm as to ensure coverage of the channel and any possibility of dealignment. The reproducibility of the method was tested by using 15 replicates for each ablation setting variation. Before surface characterization, samples were sonicated with Milli-Q water for 10 minutes and air dried.
PMMA sheets were attached to a sheet of PSA and laser cut to form the base and top of the disk. These PMMA layers also contained the air release outputs and sample input ports. The laser system used for cutting the PMMA and PSA layers was a continuous wave CO2 laser (Universal Laser Systems, VLS3.50, 30 W, 10.6 μm) with 30 W and scan speed of 12.5 mm s−1. Three-point alignment was used to align the disks. A manual cold roll laminator was used to join all the disk layers and better seal the disks, forming the microfluidic disk (Fig. 1A). The ESI† shows the different layers and disk assembly cross-section view of the assembled disk.
Fig. 1 (A) The assembled disk showing the circuits with valves and control circuits. (B) The zoomed circuit. (C) The microfluidic device made to measure the contact angle inside the channel. See ESI† for dimension details. |
A microfluidic device with modified top and bottom surfaces was created to measure the contact angle of the droplets being compressed by the top and bottom walls, mimicking a microfluidic channel containing the top and bottom modified surfaces. The device dimension was a square 50 × 50 mm, made using the same layering of the disks. This mimicking device had four corners that each contained opening “gaps” of 20 mm (Fig. 1C) used to add the fluid to the device. The modified surface dimensions in this device were 6 × 6 mm (top and bottom) and located at the centre of the device. A flat-top needle was used to insert the sample (Milli-Q water) at 90° relative to the light source and camera. The goniometer used in the previous section was used to verify the contact angle inside the device. See ESI† for device dimensions.
Fig. 2 Advancing (Adv), Receding (Rec) and Static (Sta) contact angles of surface modifications with different spacings and control (numerical table in Appendix E†). |
The surface morphology was investigated using a SEM. The hydrophobic surface demonstrated a high increase in roughness (Fig. 3). The main cause for this roughness was the non-linear absorption by the PC of the high-intensity near-infrared femtosecond laser pulse.34 It is important to note that the non-thermal mechanism of femtosecond laser treatment should generate a minimal polymer melting and reflow, as the heating generated during the process should be insufficient to melt the polymer.
In addition to the SEM analysis, the utilization of an optical profiler system revealed clear images showcasing the formation of uniform crests of identical height on the non-ablated area created by the larger line spacings. These crests were seen in all but the 40 μm spacing as seen in Fig. 4. Furthermore, it was verified that the lower spacing ablation generated an irregular surface that varied approximately 4 μm in height. The highest ablation spacing (55 μm), which generated the highest hydrophobicity, using 13 mW power generated 20 ± 3 μm grooves whilst 5 mW power gave 15 ± 2 μm. This change in power had minimal impact on the hydrophobicity of the advancing and receding contact angles, suggesting that the hydrophobic components and the depth of these crests created by varying power levels had limited influence. In addition, the results from the optical profiler indicated that the dimensions of the crest tops did affect the hydrophobicity and worked as organized micropatterns that are well-known to create hydrophobic surfaces.
Fig. 4 Optical profile measurements on top view and cross-section view for hydrophobic surfaces at different line spacing for 13 mW laser power. |
Fig. 5 Super hydrophilic surface created on PC, showing the crests and smooth surface produced by the nanosecond laser. |
The samples ablated using smaller spacing (8 μm) showed smaller wave patterns than the larger spacing lines as seen in Fig. 6. The wave top formed during ablation for the 8, 10 and 12 μm were 10.0 ± 0.7, 5.5 ± 0.8 and 6.0 ± 1.0 μm below the ablation surface, and the bottoms of the waves were at 15.0 ± 1.0, 12.0 ± 0.8 13.0 ± 1.0 μm.
The grooves in the waves lead to the formation of smooth open capillaries, which were approximately 10 μm in width and 5.0, 6.5 and 7.0 μm in depth. The formation of these open micro-channels capillaries within the ablated area maybe one of the factors responsible for creating the capillary force that pulls the liquid into the surface, contributing to the effectively zero-contact angle of the sample. Similar capillary like effects can be seen in literature as fluid can follow paths in structured surfaces.48 A small qualitative experiment was performed, where a droplet was added to a nanosecond modified surface and top images were taken over time. The images show that we can produce capillaries made with the nanosecond laser, hence showing the fluid pull and direction on open surfaces (see ESI†). Fig. 7 shows the super hydrophilicity of the surface modified by the nanosecond laser compared to the control untreated PC and the hydrophobic surface created by femtosecond laser treatment.
Fig. 7 (A) PC unmodified surface (78.5°), (B) femtosecond laser modified surface (145°) and (C) nanosecond laser modified surface and its hydrophilic wetting behaviour. |
The last wettability characterisation explored the influence of the laser induced chemical modification through a possible insertion of chemical groups (hydrophobic or hydrophilic) that may have affected the interaction in the solid–liquid interface. The modified surfaces were coated with gold at few nanometre thickness in order to hinder the hydrophilic effects due to the change in surface chemistry, turning the hydrophilic surfaces into hydrophobic ones (Fig. 8). The static contact angle for 8,10 and 12 μm spacing samples were respectively 99 ± 3°, 128 ± 3°, 144 ± 4°. Therefore, this increase in contact angle confirmed that the hydrophilicity was due to the chemical change of the material (studied in the next section). Furthermore, the airgap caused by the waves induced a Cassie-state of wettability, where the air pockets, located within the waves crests, induced the increase in contact angle seen after the hydrophilic groups were covered by gold.49
Fig. 9 ATR-FTIR spectra of the three PC surfaces, normalized to the same height for the CH 2996 cm−1 and overlaid for comparison. |
The main peaks visible in the spectra are the C–H stretch modes coming from the methyl groups between 2800 to 3000 cm−1, the sharp carbonyl stretch around 1770 cm−1, the sharp phenol ring stretch at 1501 cm−1, the carbon–oxygen stretch (C(O)C) modes appearing as a broad, multicomponent band at 1220 cm−1, the sharp C–O–C stretches at 1011 cm−1 and 840–900 cm−1, the out-of-plane deformations of the para-disubstituted phenol rings at 830 cm−1 with their C–H deformation modes at 695–765 cm−1 and the CH3 rocking modes between 910–970 cm−1.50,51 Smaller bands due to the C–H stretch modes of the phenol rings are present at 3100–3000 cm−1.52
Notable distinctions can be observed in terms of relative intensities, bandwidths, and shifts within certain spectral bands subsequent to the laser treatment of the surface. These changes indicate surface chemistry modification resulting from thermal degradation, particularly for the nanosecond-lasered surface. In the nanosecond treated surfaces, there is a clear broadening and increase in the relative intensities of the CO and O(C)O stretch modes around 1770 cm−1 and 1218–1011 cm−1, respectively. Similar changes were also observed for the deformation and twisting bonds for the chains (CH2). This could be explained by a greater thermal degradation of the PC structures resulting in scission of the polymer chains followed by branching, eventually leading to crosslinking and gelation or reflow of the surface material.53,54 This drastic change may have increased branching and disorder of the structure accompanying degradation of the carbonate groups with formation of branched products, as shown in the reactions (6) and (7) below.53 Thermal degradation of PC has been shown to involve a finely balanced competition between scission and X-linking processes.53,54
(6) |
(7) |
Increased hydrogen bonding from the crosslinking would also explain the slight red shifting and broadening of the CO stretching mode at 1770 cm−1 for the nanosecond laser treated samples. For the femtosecond treatment a slight broadening and increase in frequency and intensity were observed in the CO stretch modes at 1221 cm−1. Furthermore, a small broadening in these bands indicated a structural change due to a small thermal effect, but in considerably lower effects than the nanosecond treatment. In addition, a small increase occurred in intensity of the CC stretch mode for the aromatic ring. The changes to the femtosecond ablated surface are far smaller than those induced by the nanosecond uv laser as the thermal damage by the infrared femtosecond laser technique is small.
The different degradation conditions experienced during nano- and femto-second laser treatments resulted in different surface modifications of the two PC samples. Both show an increase in the hydrophilic groups, significantly larger for the nanosecond laser treatment. This observation supports an earlier finding that a slight alteration in degradation conditions can drastically change the overall mechanism of breakdown and breakdown products.54
Another characterisation technique used to measure the differences in hydrophobic and hydrophilic groups can be obtained from XPS peak ratios, as shown in Fig. 10. The spectra were fitted based on peak assignments determined from Smith et al.,55 with well-known binding energies for each carbon functionality. Overall, the XPS showed an increase in the carbonyl (CO) and C–O functionalities (C(O)O) relative to pure C–C or CC functionalities with a slight increase in surface oxygenation with nanosecond compared to femtosecond laser treatment. This apparent discrepancy compared to the FTIR results can be understood by the highly surface sensitive nature of XPS, which only collects photoelectron signals from within the first few nanometres of a surface.56 Therefore, the femtosecond laser treated region could have a highly oxidised surface layer, but a much less thermally damaged/perturbed interior, as FTIR probes the surface composition to a depth at the low micron range.57 The combined evidence then points to nanosecond laser treatment inducing a large increase in the oxygen content, with femtosecond lasers only changing the surface oxygen content (at least a few nm deep) while leaving most of the laser interaction volume free from additional oxidation. Table 1 shows the functional group percent ratio in the analysed surface. The ππ* signal due to the aromatic rings shows s a small increase for the femtosecond laser treatment compared to control and nanosecond.
Area% | C–C | C–O | C(O)O | ππ* | C(O)O/C–C | C–O/C–C |
Control | 84.66 | 11.17 | 3.24 | 0.93 | 0.04 | 0.13 |
Femtosecond | 50.43 | 33.77 | 12.79 | 3.01 | 0.25 | 0.67 |
Nanosecond | 46.81 | 36.41 | 14.27 | 2.51 | 0.30 | 0.78 |
Likewise, the ratio of the hydrophobic component C–C is higher for the femtosecond compared to the nanosecond treatment, where both have less C–C component than the control. The ratio for the hydrophilic groups C(O)C and C–O are increased for the laser treatments, having higher values for the nanosecond laser treatment. Therefore, a higher surface oxidation occurs for the nanosecond laser ablation, confirming the effect of surface modification that led to the formation of the highly hydrophilic surfaces seen in the previous sections.
Moreover, the application of a nanosecond laser pulse, in addition to ensuring a smooth surface, facilitated the creation of super hydrophilic surfaces by inducing a higher concentration of hydrophilic groups. This process relied predominantly on the localized heating and subsequent material removal through vaporization or melting, as evident in the observed melting characterisation seen in the optical profile section (Fig. 6). Unlike the femtosecond process, the use of a slower laser pulse with a highly absorbed wavelength allowed material removal and surface modification, without causing significant roughness or microstructure formation. Additionally, the reflow of the polymer further contributed to the attainment of a smooth surface and hence, to the maintenance of the superhydrophilic properties of the chemical groups.
The creation of laser-modified surfaces is influenced by various factors, including the instrument's precision and the specific settings employed. For instance, Liu et al.7 utilized a UV laser with higher wavelengths (355 nm) and fluences that were 100-fold greater than those utilized in our experiment, resulting in the generation of hydrophilic rough surfaces. Conversely, Meunier et al.17 achieved smooth lenses by employing femtosecond lasers with low laser excitation at the nanojoule level beneath the surface. These studies demonstrate that laser settings, such as power, wavelength, speed, and other variables, can generate surfaces with different morphologies, chemistries, and wettability properties.
In our study, we successfully generated smooth surfaces using a nanosecond UV laser and rough surfaces using femtosecond IR laser settings, both of which exhibited highly defined patterns. This showcases different methods for creating hydrophobic and hydrophilic surfaces. Notably, our technique offers advantages in terms of precision, with precise wave patterns, smooth surfaces, and modified area reproducibility. However, similar to other existing direct laser modification techniques, its current limitation lies in the speed required for mass production applications, such as in the fabrication of microfluidic chips. Even having some limitations, these techniques serve as valuable prototyping methods to demonstrate concepts, as exemplified in our subsequent section, and hold the potential to pave the way for the future of precise microfluidic and nanofluidic device fabrication.
It is worth noting that the field of microfluidics is increasingly converging towards nanofluidics, necessitating improved fluid control in microfluidic chips. Therefore, enhancing the speed of these systems may define the next phase in microfluidics' development. Good candidates such as spatial light modulators may one day be used to speed these processes.62,63
Fig. 11 Inner view of the fluid behaviour within different top and bottom surfaces. (top) Untreated surface, (middle) hydrophobic and (bottom) hydrophilic surfaces and their wettability angles. |
The experimental setup ensured the channels' walls and dimensions remained constant throughout the study (Fig. 12). Calculations were based on the advancing contact angles observed, which closely resemble the behaviour of droplets passing through the modified patches. Comparing the effects of different surface treatments (nanosecond and femtosecond laser) to the control group revealed unique and distinct impacts on the behaviour of liquid droplets.
Fig. 12 Top view of the microfluidic channel with fluid showing θh, where the angles are shown in red. |
The hydrophobic valves showed an increase in the necessary burst frequency from 649 ± 50 to 818 ± 35 rpm, leading to an experimental pressure (using eqn (5)) increase from 349 ± 55 to 490 ± 42 Pa, an increase of approximately 29% in the pressure required to burst the hydrophobic valves compared to the control. The theoretical pressure was calculated by applying eqn (5). The results were respectively 352 ± 25 and 488 ± 20 Pa, for the control and hydrophobic valve, agreeing with the experimental values. One important finding was the fluid stoppage that occurred on the initial part of the modified surface patch, creating an initial hydrophobic barrier, followed by slow constriction of the fluid until it reaches the end part of the modified surface.
The fluid movement behaviour on the hydrophilic surface showed distinct fluid movement phases when passing through the hydrophilic valve. The first stage consisted of a “speed lane”, which happened as a droplet touched the modified surface. The presence of a high surface energy on the hydrophilic patch promptly pulled the droplet, facilitating its motion until it reached the boundary where the unmodified area began. Hence, the pressure necessary to move the droplet decreased, due to the high surface energy created by the chemical modification. However, as soon as the droplet touched the lower surface energy, unmodified area, it needed more pressure to overcome the hydrophilic patch as the water gets held by the high surface energy of the hydrophilic patch. In practical application, the hydrophilic valve demonstrated comparable efficacy in retaining a water droplet when compared to the hydrophobic valve. Fig. 13 shows these stages.
The fluid entered the hydrophilic patch at 663 ± 48 rpm, which was approximately the same speed necessary to burst the control channel. The calculated burst pressure using the contact angle and dimension measurements resulted in 223 ± 20 Pa. However, as soon as the droplet meniscus began to overcome the valve, the fluid was held by the highly hydrophilic surface (as seen in Fig. 13C) and 803 ± 39 rpm was required to burst the valve, resulting in extra 140 ± 29 rpm for the burst frequency to burst the surface modified area. This difference applied to the the calculated burst pressure resulted in 213 ± 35 Pa, a decrease of approximately 39% in the pressure required to move the droplet through the channel. Hence, the droplet entering the channel had a reduced pressure, however, leaving the channel the force exerted needed to be increased by increasing the RPM. The results are summarized in Table 2.
Control | Hydrophobic | Hydrophilic | |
---|---|---|---|
θw (°) | 80 ± 2 | 158 ± 5 | 17 ± 2 |
θh (°) | 41 ± 4 | 41 ± 4 | 41 ± 4 |
W (μm) | 679 ± 40 | 710 ± 35 | 666 ± 38 |
H (μm) | 375 ± 15 | 375 ± 15 | 375 ± 15 |
Burst frequency (rpm) | 649 ± 50 | 818 ± 35 | In: 663 ± 48 |
Out: 803 ± 39 | |||
Theoretical P (Pa) | 352 ± 25 | 488 ± 20 | 223 ± 20 |
Experimental P (Pa) | 349 ± 55 | 490 ± 42 | In: 213 ± 35 |
Out: 480 ± 43 |
The results revealed two main distinct potential applications for the hydrophobic valves. Firstly, they can effectively halt the flow of fluids during the initial sample insertion into the microfluidic device, enabling enhanced precision in sample measurements. Secondly, as microfluidic circuits continue to decrease in size and channel dimensions become smaller, capillary force can intensify, leading to a potential fluid leakage issue in subsequent chambers before the appropriate time. These valves can be used to prevent these fluid leaks happening from chamber to chamber or even the fluid entering a channel.
Similarly, to the hydrophobic valves, the hydrophilic valves have also increased the burst pressure necessary to allow fluid movement. However, due to its different fluidic behaviour, one possibility to be investigated is the use of its liquid engulfing as means to increase the strength of the mixing force applied in open droplets. Therefore, as centrifugal microfluidic miniaturizes even further, hydrophilic patches could be used to hold microdroplets in position, whilst applying a higher acceleration and deceleration (Euler force) and take advantage of mixing at micro or nanoscale.65 An additional potential application to explore is their utilization as a platform to expedite and direct the transfer of liquids between microfluidic chambers. By employing a hydrophilic surface on both the channel and chamber in one configuration, and leaving another channel and chamber unmodified, the modified channel and chamber can receive the liquid before reaching the pressure threshold required to induce fluid movement through the unmodified surfaces. Finally, one of the fields in microfluidics that can take advantage of such hydrophilic surfaces is the open-air microfluidic circuits that need fluids to use capillary force and at the same time need the fluid to be held by such capillaries.25
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d3ra01749d |
This journal is © The Royal Society of Chemistry 2023 |