Thermal lamination and laser cut (TLLC) method for enclosed Micro-fluidic paper analytical devices (μPADs) by controlled ablation
Year: 2026
Type: article
Abstract: We introduce a novel, simple, and highly scalable fabrication method—thermal lamination and laser cut (TLLC)—for the rapid and cost-effective production of fully enclosed paper-based microfluidic analytical devices (µPADs). The process combines standard office lamination with controlled laser ablation, simultaneously defining device architecture, opening inlet zones, and creating void trenches that function as intrinsic hydrophobic barriers for reliable capillary-driven fluid confinement. For the fabrication of standard high-throughput formats such as 96-well plates, we added a high-temperature flash lamination step that promotes glue infiltration into the trenches, yielding robust physical barriers. This preserves fluid volumes throughout the assay for consistent reaction dynamics across the samples. Device performance was validated through colorimetric glucose sensing assays and fibroblast proliferation studies in the 3D paper matrix. The experiments confirmed the device’s diagnostic utility and suitability as a 3D cell culture platform. TLLC supports quick fabrication of enclosed channels resistant to contamination and evaporation, as well as standard 96-well plate reservoirs for large-volume assays. By consolidating fabrication into a streamlined two-step process that relies on ubiquitously available materials and automatable commercial tools, the method enables high-speed mass production at low cost, while enhancing mechanical stability and reproducibility. TLLC presents a remarkable edge in µPAD technology, offering an efficient platform for large-scale deployment in diagnosis, biomedical research, and tissue culture applications.
Source: Sensors and Actuators Reports
Institutions: New York University Abu Dhabi, New York University
Language: English
Subfield: Biomedical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,430
OpenAlex ID: W7126087823