3D-printed shadow masks for micro-patterned electrodes

Microfabrication is critical to the advancement of lab-on-chip devices by enabling the creation of high-precision, complex electrode structures. Traditional photolithography, commonly used to fabricate micro-patterned electrodes, involves complex and multi-step processes that can be costly and time-consuming. In this research, we present a method using 3D-printed shadow masks for electrode fabrication, offering a simpler, cost-effective alternative to traditional methods. Specifically, by leveraging a fused deposition modeling 3D printer, we demonstrate that 3D-printed shadow masks streamline rapid prototyping of micro-patterned electrodes with a range of designs, from simple lines to complex patterns. To assess the lab-on-chip functionality of the electrodes fabricated from 3D-printed shadow masks, we investigate electric field-driven assembly of microparticles in the electrodes. The micro-patterned designs of the electrodes remotely guide the assembly patterns, resulting in the formation of well-defined, multiple chains and anisotropic structures. These results suggest that 3D-printed shadow masks not only simplify the fabrication process, but also maintain the precision required for advanced lab-on-chip applications. The proposed method could pave the way for more accessible and scalable manufacturing of the complex micro-patterned electrodes.