Microfluidic Device Fabrication: Techniques, Materials, Integration Strategies and Commercialization Prospects

Microfluidic devices allow precise manipulation of fluids at the microscale, transforming biomedical, chemical, and environmental applications. This paper reviews key fabrication techniques, including photolithography, soft lithography, three-dimensional printing, laser micromachining, and paper-based methods, comparing their resolution, cost, speed, and scalability. It discusses materials such as polymers, glass, silicon, and hydrogels, emphasizing factors like biocompatibility, transparency, and strength. The integration of fabrication processes with material properties, along with challenges and optimization strategies, is analysed. Recent advances in sustainable fabrication, smart materials, and artificial intelligence-assisted design are explored. The study concludes with insights into patents, emerging technologies, and commercial potential in microfluidics.