Optimized process for the fabrication of PDMS membranes integrating permanent micro-magnet arrays

Here we report on the fabrication of micro-magnet arrays by powder agglomeration in a polymer matrix. The NdFeB@polydimethylsiloxane (PDMS) inner microstructure and the generated magnetic forces were studied, when prepared under two different magnetic field configurations. The initial process uses the classical crosslinking of PDMS mixed with NdFeB powder under a low magnetic field gradient provided by a permanent magnet (LG set-up for low gradient). In contrast, the optimized process uses an intermediate layer, composed of iron microstructures in a PDMS matrix that amplifies and focuses the magnetic field gradient given by the permanent magnet (HG set-up for high gradient). Both processes result in a heterogeneous material that can be described as an array of permanent micro-magnets diluted in a non-magnetic host matrix. The NdFeB@PDMS microstructure was characterized by X-ray tomography and optical microscopy. The magnetic properties were also measured by magnetometry and colloidal probe AFM. Results showed that the HG set-up leads to an array of micro-magnets localized at the surface, with higher compactness and density, resulting in stronger magnetic performances compared to the LG set-up. This technology only implies easy-to-handle and cheap fabrication processes, paving the way for the development of low-cost lab-on-chip devices integrating magnetophoretic trapping functionality.