Leveraging Millimeter-Scale Multi-Material Manufacturing for Biomedical Devices

Abstract

This thesis explores the use of precision laminate manufacturing to develop millimeter-scale biomedical devices that enable new capabilities in soft-tissue attachment, biological fluid sampling, and integrated sensing. Millimeter-scale devices are transforming minimally invasive medicine by allowing tools to be ingested, injected, or delivered through natural orifices, accessing previously unreachable areas of the body with minimal trauma. We present three proof-of-concept devices that demonstrate how laminate-based design unlocks new clinical functions. First, we draw inspiration from parasitic organisms such as Taenia sp. to replicate their mechanical anchoring strategies with rotating hook-like elements that latch into tissue with minimal damage. Second, we develop a modular gastrointestinal fluid-sampling capsule designed to collect microbiome-rich samples from hard-to-reach regions of the GI tract. The capsule architecture supports interchangeable modules for actuation, one-way fluid control, sample storage, and triggering. Third, we propose a set of customized sensors tailored to patient-specific anatomy and constraints. These devices are fabricated using multi-material micromanufacturing techniques that combine laser machining, lamination, and origami-inspired folding to integrate complex mechanisms at the millimeter scale. The modular design principles established here provide a foundation for future adaptive, patient-specific, and scalable biomedical tools.