Positive replicas were fabricated in PDMS (Sylgard® 184 Silicone Elastomer Kit, Dow Corning) by curing the pre-polymer (a mixture of 10/1 w/w base and the curing agent) on the printed masters at 60°C for 2 hours, accordingly with the previously described protocol [16]. The PDMS mold was removed from the printed master by manually peeling it off (demolding). This procedure resulted in replicas with intruded and top-opened channels with rectangular cross-sectional geometry, as a result of the negative 3D-printed master. The patterned replica was bonded to a PDMS flat layer (i.e. a closing layer of 175 mm x 70 mm x 1 mm in size), that was previously fabricated by casting and curing PDMS pre-polymer in a proper plastic master fabricated by standard stereolithography. Both masters were then reused without additional cleaning processes.

Once demolded, both the fabricated PDMS layers were irreversibly sealed together, resulting in a final polymer device. In details, the sealing procedure is the following. Firstly, a pre-polymer film was deposited directly on a 200 mm x 200 mm glass plate, with a thickness lower than 50 μm. Then, the patterned replica and coated glass were arranged to allow a fast inking contact (5 minutes) between the open-side of the replica’s channels and the film. Successively, the replica was manually detached from the coated glass and exposed to partial curing at 60°C for no more than 5–8 minutes, obtaining a sticky side. Then, the sticky layer was placed in contact with the closing layer and bonded together by curing in oven at 60°C for 30 minutes. Finally, the plastic tubes of the circuit were connected to the holes at the extremities of the channel and permanently sealed by applying the pre-polymer at the interfaces, and by curing it at 60 ˚C for 30 minutes to fix the connection.

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