Building on the foundation of the 2D-Experimental Pilot line project (2D-EPL), the 2D-Pilot line project, 2D-PL, has the ambition to further strengthen the European ecosystem in the development of the relevant integration modules for offering prototyping services in the field of photonics and electronics, working on the maturation of the technology, and providing essential information aiding industrial uptake. The main objective of the pilot line is to further mature 2DM fabrication in an industrially relevant FAB environment to secure the 2D pilot line access. The service offerings include the preparation of relevant process design kits (PDKs) and multi-project wafer (MPW) run offerings, which are an essential part of this project's outreach plan. The large application space for 2DM and the broad differentiation for material property requirements make the development of such a pilot line very challenging. Therefore, within the scope of the 2D-PL project, the focus for module maturation is tailored towards the photonic and electronic devices and circuits reaching academic institutions, research centres, SMEs, and larger businesses.

The project aims at a holistic new design strategy, coordinated pilot lines and business model for the prototyping, fabrication and commercialization of polymer-based microfluidic systems. It stems from the recognition that a microfluidic chip is a key part of a microfluidic MEMS, but only a part. Many limitations to fast prototyping, industrialization and ultimate performances lie not in the chip itself, but in the world-to-chip connections and integration of multiple external components. We shall address in a single strategy the streamlined construction of whole microfluidic systems, starting from existing pilot lines in injection moulding, 3D printing and instrument construction. This will specific innovations. First, the resolution of 3D printing will be increased by a factor at least 10, down to 1~3µm, with a throughput 10 to 100x higher than that of current high resolution 3D printing machines, to support the flexible production of chips with complex 3D architectures. New soft, bio, environment-friendly and/or active materials will be integrated in the production chain using a technology patented by the partners. Large-scale markets requiring mass production at the lowest cost will be addressed by a fully integrated pilot line, streamlining injection moulding of raw chips, reagents and components integration, sealing and quality control. Inter-compatibility between 3D printing and injection moulding, regarding architectures and materials, will be developed to accelerate the prototype to product value chain. After development and upscaling, the technology will be demonstrated and qualified in operational environment by end-users with lab-on-chip applications in health (cancer diagnosis, organ-on chip) and environment (water control). Partners jointly have the production lines onto which the project’s innovation will be readily integrated, helping microfluidics to become a major component of the 4th industrial revolution.

Roll-to-roll (R2R) technologies are mature core processes in manufacturing lines for graphical printing industry. In several other areas (e.g. electronics or optics) R2R techniques are emerging, being expected to notably lower the unit prices of flexible devices. In particular, recently developed roller-based nanoimprinting methods enable unrivalled throughput and productivity for precise fabrication of micro- and nanoscale patterns. Areas that will benefit strongly from adopting such R2R nanoimprinting technologies are microfluidics and lab-on-chip products for diagnostics, drug discovery and food control. Such devices require combined printing of micro- and nanostructures and large quantities at low unit costs. The project R2R Biofluidics aims on the development of a complete process chain for first-time realization of production lines for two selected bioanalytical lab-on-chip devices based on high-throughput R2R nanoimprinting in combination with complementary printing and manufacturing technologies. Two types of demonstrators will be fabricated targeting application areas, which would clearly benefit from technology advancement in high volume manufacturing, show large potential for commercial exploitation and adopt current standard formats (microtiter plate and microscope slides). Demonstrator 1 will represent an in-vitro diagnostic (IVD) chip suitable for point-of-care applications, showing improved sensitivity thanks to imprinted nanoscale optical structures and microfluidic channels. R2R fabrication will further greatly reduce production costs and increase manufacturing capacity with respect to currently used products. Demonstrator 2 will provide a device for improved neuron based high-throughput screening assays in drug development. It will consist of nano– to microstructured, interconnected channels in combination with dedicated biofunctionalized surfaces for alignment and controlled growth of neurons.