Stiffness influence on particle separation in polydimethylsiloxane-based deterministic lateral displacement devices

Polydimethylsiloxane (PDMS) is a popular material to rapidly manufacture microfluidic deterministic lateral displacement (DLD) devices for particle separation. However, manufacturing and operation challenges are encountered with decreasing device dimensions required to separate submicron particles. The smaller dimensions, notably, cause high hydraulic resistance, resulting in significant pressure even at relatively low throughputs. This high pressure can lead to PDMS deformation, which, in turn, influences the device performance. These effects may often be overlooked in the design and operation of devices but provide a systematic source of error and inaccuracies. This study focuses in detail on these effects and investigates pillar deformation in detail. Subsequently, we discuss a potential solution to this deformation using thermal annealing to stiffen the PDMS. We evaluate the influence of stiffness on the separation performance at elevated sample flow rates with submicron particles (0.45 and 0.97 µm diameter). An excellent separation performance at high throughput is successfully maintained in stiffer PDMS-based DLD devices, while the conventional devices showed decreased separation performance. However, the increased propensity for delamination constrains the maximal applicable throughput in stiffer devices. PDMS deformation measurements and numerical simulations are combined to derive an iterative model for calculating pressure distribution and PDMS deformation. Finally, the observed separation characteristics and encountered throughput constraints are explained with the iterative model. The results in this study underline the importance of considering pressure-induced effects for PDMS-based DLD devices, provide a potential mitigation of this effect, and introduce an approach for estimating pressure-induced deformation.