Integrated Size-Selective Cell Purification and Electroporation for Genetic Manipulation of Primary Cells

Biologically relevant primary cell samples are inherently heterogeneous and often require selective enrichment prior to genetic manipulation. We previously demonstrated a vortex-assisted microfluidic platform that integrates size-selective cell trapping with electroporation; however, its limited processing capacity constrained applications requiring larger sample volumes. Here, we present a scaled version of this integrated system achieved through electrode array redesign and electrical optimization. The updated architecture increases processing capacity while preserving size-selective trapping behavior, electric field uniformity, and device stability. Systematic optimization of electrical and buffer conditions enables efficient delivery of plasmid DNA and in vitro-transcribed mRNA into primary human cells, with performance approaching benchmark chemical transfection methods. By scaling an integrated trapping-electroporation workflow without compromising delivery performance, this platform advances microfluidic cell engineering toward practical processing of heterogeneous primary cell samples.