Laser‐Patterning of Micromagnets for Immuno‐Magnetophoretic Exosome Capture

Abstract Efficient isolation and patterning of biomolecules is a vital step within sample preparation for biomolecular analysis, with numerous diagnostic and therapeutic applications. For exosomes, nanoscale lipid‐bound biomolecules, efficient isolation is challenging due to their minute size and resultant behavior within biofluids. This study presents a method for the rapid isolation and patterning of magnetically tagged exosomes via rationally designed micromagnets. Micromagnet fabrication utilizes a novel, scalable, and high‐throughput laser‐based fabrication approach that enables patterning at microscale lateral resolution (<50 µm) without lithographic processing and is agnostic to micromagnet geometry. Laser‐based processing allows for flexible and tunable device configurations, and herein magnetophoretic capture within both an open‐air microwell and an enclosed microfluidic system is demonstrated. Patterned micromagnets enhance localized gradient fields throughout the fluid medium, resulting in rapid and high efficiency magnetophoretic separation, with capture efficiencies nearing 70% after just 1s within open‐air microwells, and throughputs upward of 3 mL h −1 within enclosed microfluidic systems. Using this microchip architecture, immunomagnetic exosome isolation and patterning directly from undiluted plasma samples is further achieved. Lastly, a FEA‐based modeling workflow is introduced to characterize and optimize micromagnet unit cells, simulating magnetophoretic capture zones for a given micromagnet geometry.