Analysis of a miniaturized 3D PDMS channel deflector fabricated using lost-wax casting

The Taguchi method and numerical simulations were used to determine the significant parameters of a 3D deflector in channel flow. The lost-wax casting method was used to fabricate polydimethylsiloxane (PDMS) channels with a 3D deflector. Once fluid passes through the deflector, it will induce vortexes in the channel, causing flow separation, stretching, twisting, and interactions with the fluid already in the channel. Better mixing ratios can be achieved with a stronger vorticity. Our methods and measurements demonstrated the fidelity of the replication process from the original CAD file to the PMMA mold, wax pattern, and PDMS channel. Compared to other microfabrication methods, such as injection molding, micromachining, and hot embossing, lost-wax casting is a successful method for producing a 3D deflector in a PDMS channel.