Parylene-C Modified OSTE Molds for PDMS Microfluidic Chip Fabrication and Applications in Plasma Separation and Polymorphic Crystallization

This work presents a novel microfabrication process that addresses the interference of thiol groups on off-stoichiometry thiolene (OSTE) surfaces with the curing of polydimethylsiloxane (PDMS) by integrating the high-performance polymer Parylene-C. The process utilizes a Parylene-C coating to encapsulate the active thiol groups on the OSTE surface, enabling precise replication of PDMS microstructures. Based on this method, PDMS micropillar arrays and microwell arrays were successfully fabricated and applied in passive plasma separation and polymorphic crystal formation, respectively. The experimental results demonstrate that the plasma-separation chip efficiently isolates plasma from whole-blood samples with varying hematocrit (HCT) levels, achieving a separation efficiency of up to 57.5%. Additionally, the microwell array chip exhibits excellent stability and controllability in the growth of salt and protein crystals. This study not only provides a new approach for microfabricating microfluidic chips, but also highlights its potential applications in biomedical diagnostics and materials science.