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Injection molded microfluidic chips featuring integrated interconnects.

Dieudonne A Mair1, Emil Geiger, Albert P Pisano

  • 1Department of Chemical Engineering, University of California, Berkeley, CA 94720, USA.

Lab on a Chip
|November 15, 2006
PubMed
Summary
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This study presents a rapid injection molding process for disposable microfluidic chips using cyclo-olefin copolymer (COC). The developed chips offer high-pressure resistance and integrated interconnects, enabling in situ monolith preparation.

Area of Science:

  • Materials Science
  • Microfluidics Engineering

Background:

  • Disposable microfluidic devices are crucial for point-of-care diagnostics and lab-on-a-chip applications.
  • Existing fabrication methods often face challenges in speed, cost, and achieving high-pressure compatibility.

Purpose of the Study:

  • To design and implement a rapid injection molding process for disposable microfluidic chips.
  • To identify a suitable cyclo-olefin copolymer (COC) for microfluidic chip fabrication.
  • To develop high-pressure resistant chips with integrated interconnects.

Main Methods:

  • Screening of sixteen cyclo-olefin copolymer (COC) grades for UV transparency and autofluorescence.
  • Rapid microfabrication of a solid metal mold insert using an electroplating process.
  • Injection molding of microfluidic chips with a 2-minute cycle time.

Related Experiment Videos

  • Thermal fusion bonding of chips and burst pressure testing.
  • Demonstration of chip functionality via in situ porous polymer monolith preparation.

    • Main Results:

    • Topas 8007 x 10 identified as the optimal COC grade.
    • Mold insert demonstrated robustness with no wear after over 1000 cycles.
    • Developed microfluidic chips withstand pressures up to 15.6 MPa.
    • Integrated interconnects enable high-pressure, reversible connections.
    • Successful in situ preparation of high surface area porous polymer monoliths.

    Conclusions:

    • A rapid and robust injection molding process for disposable COC microfluidic chips has been successfully developed.
    • The fabricated chips exhibit exceptional high-pressure resistance and integrated interconnects, surpassing previous reports.
    • These UV-transparent, disposable microfluidic devices are suitable for advanced applications, including in situ sample preparation.