Size-Based Separation of MCF-7 Breast Cancer Cells and White Blood Cells Using a Custom-Made 3D-Printed Microfluidic Chip

Traditional methods for cell separation, such as density gradient centrifugation and flow cytometry, are limited by factors like large sample volumes, high costs, and the potential for cellular damage. In contrast, microfluidic-based sorting provides a compact, cost-effective, and high-throughput platform with minimal mechanical stress. This study evaluates the performance of a commercial spiral microfluidic chip and a custom-made 3D-printed chip for size-based separation of MCF-7 breast cancer cells and white blood cells from a spiked sample. The custom-made 3D-printed chip was fabricated using Digital Light Processing 3D printing, offering rapid prototyping and high precision. Experimental results demonstrate the efficient separation of MCF-7 cells, with a high recovery rate, and suggest that the 3D-printed chip performs comparably to commercial alternatives. The study highlights the potential of 3D-printed microfluidics for label-free cell separation, with promising applications in circulating tumor cell isolation, single-cell analysis, and personalized medicine. Further refinement of chip geometry and optimization of flow conditions could enhance sorting precision and scalability, making this approach a valuable tool for both diagnostic and research applications. Additionally, structural health monitoring (SHM) and nondestructive testing (NDT) techniques play a crucial role in aerospace applications, ensuring the integrity and reliability of components subjected to extreme conditions. These methodologies could be further explored to assess and enhance the fabrication quality of 3D-printed microfluidic chips, bridging the gap between biomedical and aerospace applications.