Comparative analysis of fabrication methods for achieving rounded microchannels in PDMS

Many microfluidic applications demand control over channel cross-sectional geometry. In particular, rounded microchannels are essential to the function of microfluidic valves, which have played an integral part in the success of microfluidics over the past fifteen years. Here we investigate the relative strengths and weaknesses of different strategies for fabricating rounded microchannels in PDMS, systematically examining five common strategies. We consider the appropriateness of the fabrication strategies for microchannels of differing sizes and aspect ratios, and evaluate these various strategies on a number of metrics ranging from microchannel resolution to fabrication difficulty. We discuss the merits of the different strategies for a range of applications, and make recommendations on which strategy to use based on the driving constraints of the device.