Fabrication of a microfluidic system with in situ-integrated microlens arrays using electrohydrodynamic jet printing

Microfluidic systems with integrated microlenses enhance cellular analysis and observation and have gained significant attention in the biomedical field. However, the integration and design of microlenses in microfluidic systems remain challenging. In this study, we utilize a high-precision electrohydrodynamic jet (E-jet) printing system for in-situ integration of microlens. By incorporating a tilting illumination observation module into the Ejet printing system, the print nozzle can be accurately positioned 10 mu m above the microchannel bottom, thereby mitigating the edge effect of the microfluidic channels. We have developed a microfluidic system embedding microlens arrays (MLAs) that enable parallel, multichannel cell counting. The microfluidic system comprises nine channels, each featuring a 50 mu m diameter microlens printed along the central axis. Using microlenses enables non-contact cell counting by detecting light-intensity changes. Simulating and optimizing the microfluidic channel size enable cells to align on the centerline of the channel and pass over the focal region of the microlens via inertial forces. As the cells flow through the microlens, the intensity of the focal spots decreases by approximately 50 %. The microfluidic cell-counting system can function independently or be integrated with other microfluidic systems as a unit, thus enhancing the single-cell operational and analytical capabilities of microfluidic systems.