The disclosed technology includes devices and methods for detecting rare cells in whole blood samples using a microfluidic device. Such devices include a housing with a microfluidic chamber having first and second microfluidic layers, each microfluidic layer having an array of microscale structure. Other disclosed devices also include a housing including a chemically functionalized hydrogel matrix and a pump connected to the housing. Disclosed methods include constructing, with an additive manufacturing device, a microfluidic device having a microfluidic chamber, removing, by a thermal release process, at least some of the sacrificial support material deposited by the additive manufacturing device, and chemically functionalizing at least a portion of the microfluidic chamber. Other disclosed methods include chemically functionalizing a hydrogel matrix and connecting the chemically functionalized hydrogel matrix to a pump.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

A machine for disassembling a lens mold assembly including a first mold part, a second mold part, and a molded-lens sandwiched therebetween. The machine includes a centering unit to center the lens mold assembly. The machine includes a disassembling module having a mold engagement mechanism to engage the first and second mold parts to clamp and move the lens mold assembly. The disassembling module includes a molded-lens holder mechanism having at least two clamping members to clamp the molded-lens of the lens mold assembly. The machine includes an alignment guidance module to detect relative positions between the molded lens of the lens mold assembly and the molded-lens holder mechanism to align the molded lens for clamping by the molded-lens holder mechanism. The mold engagement mechanism is configured to hold the first and second mold parts individually and to separate the first and second mold parts from the molded lens.

A machine for disassembling a lens mold assembly including a first mold part, a second mold part, and a molded-lens sandwiched therebetween. The machine includes a centering unit to center the lens mold assembly. The machine includes a disassembling module having a mold engagement mechanism to engage the first and second mold parts to clamp and move the lens mold assembly. The disassembling module includes a molded-lens holder mechanism having at least two clamping members to clamp the molded-lens of the lens mold assembly. The machine includes an alignment guidance module to detect relative positions between the molded lens of the lens mold assembly and the molded-lens holder mechanism to align the molded lens for clamping by the molded-lens holder mechanism. The mold engagement mechanism is configured to hold the first and second mold parts individually and to separate the first and second mold parts from the molded lens.

Three-dimensional (3D) hierarchical morphologies widely exist in natural and biomimetic materials, which impart preferential functions including liquid and mass transport, energy conversion, and signal transmission for various applications. While notable progress has been made in the design and manufacturing of various hierarchical materials, the state-of-the-art approaches suffer from limited materials selection, high costs, as well as low processing throughput. Herein, by harnessing the configurable elastic crack engineering-controlled formation and configuration of cracks in elastic materials, an effect normally avoided in various industrial processes, the present invention provides a facile and powerful technique to enable the faithful transfer of arbitrary hierarchical structures with broad material compatibility and structural and functional integrity. The present invention provides a cost-effective, large-scale production method of a variety of flexible, inexpensive, and transparent 3D hierarchical and biomimetic materials.

Three-dimensional (3D) hierarchical morphologies widely exist in natural and biomimetic materials, which impart preferential functions including liquid and mass transport, energy conversion, and signal transmission for various applications. While notable progress has been made in the design and manufacturing of various hierarchical materials, the state-of-the-art approaches suffer from limited materials selection, high costs, as well as low processing throughput. Herein, by harnessing the configurable elastic crack engineering-controlled formation and configuration of cracks in elastic materials, an effect normally avoided in various industrial processes, the present invention provides a facile and powerful technique to enable the faithful transfer of arbitrary hierarchical structures with broad material compatibility and structural and functional integrity. The present invention provides a cost-effective, large-scale production method of a variety of flexible, inexpensive, and transparent 3D hierarchical and biomimetic materials.

Embodiments of the invention are directed to a molding system and kit for molding a modeling compound. The molding system is generally comprised of an openable interlocking molding device, the openable interlocking molding device is configured to cast external features onto a modeling compound surface by securing the modeling compound within a molding cavity of the openable interlocking molding device. Further, the molding system includes a substrate with movable joints that is configured to be enveloped by the modeling compound prior to casting the external features onto the modeling compound by the interlocking molding device.

Embodiments of the invention are directed to a molding system and kit for molding a modeling compound. The molding system is generally comprised of an openable interlocking molding device, the openable interlocking molding device is configured to cast external features onto a modeling compound surface by securing the modeling compound within a molding cavity of the openable interlocking molding device. Further, the molding system includes a substrate with movable joints that is configured to be enveloped by the modeling compound prior to casting the external features onto the modeling compound by the interlocking molding device.

Provided is a method for manufacturing a transdermal absorption sheet which makes it possible to manufacture a transdermal absorption sheet with a stable shape. The method for manufacturing a transdermal absorption sheet includes a step of forming a drug layer (110) on needle-like recess portions (42) of a mold (50) having the needle-like recess portions (42), a step of supplying a polymer layer forming solution (112) to the inside of a step portion (52) of the mold (50), a step of drying the polymer layer forming solution (112) so as to form a polymer layer (114) and a transdermal absorption sheet (120), and a step of peeling off the transdermal absorption sheet (120) from the mold (50). In the step of peeling off, pressing force is applied to a part of the step portion (52) in a second direction (B) opposite to a first direction (A) in which the transdermal absorption sheet (120) is released from the mold (50), and the transdermal absorption sheet (120) is aspirated with a vacuum suction pad (160) from a side opposite to the mold (50) so that the transdermal absorption sheet (120) is peeled off from the mold (50) in the first direction (A).