Development of modular system structures for assembling microfluidic components of disparate materials

The primary focus of this thesis is the development of interlocking cylinder and hole microstructures as mechanical and microfluidic interconnect between microchannel containing substrates to form complex microfluidic systems. Interconnects composed of various compliant polymer cylinders and silicon or polymer holes are analysed with ANSYS to optimise interconnect design for mechanical assembly and disassembly forces, as well as fluidic properties, including pressure, dead volume, and fluid flow. Interconnects are fabricated in SU-8 photopolymer, polydimethylsiloxane (PDMS) and in-house fabricated electro-ferromagnetic composites using PDMS and iron beads. Mating structures are experimentally verified for utilisation as microfluidic interconnect between microchannel containing substrates. Their disassembly forces are experimentally tested and range from 20-130mN. Enclosed microchannels with integrated interconnect made in PDMS are also simulated, fabricated, and fluidically tested to 148kPa at 1mL/min as an example fluidic component for microinstrumentation. These structures are furthermore placed in the context of a microsystem designed for guided microassembly.