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Updated: Feb 4, 2026

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding
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Injection-Molded Microfluidic Device for SERS Sensing Using Embedded Au-Capped Polymer Nanocones.

Marlitt Viehrig1, Anil H Thilsted1, Marco Matteucci1

  • 1The Danish National Research Foundation and Villum Foundation's Center for Intelligent Drug Delivery and Sensing Using Microcontainers and Nanomechanics (IDUN), Department of Micro- and Nanotechnology , Technical University of Denmark , Ørsted Plads , 2800 Kgs. Lyngby , Denmark.

ACS Applied Materials & Interfaces
|October 3, 2018
PubMed
Summary

We developed a low-cost, mass-producible microfluidic lab-on-a-chip device using polymer injection molding and gold-capped nanocones for highly sensitive surface-enhanced Raman spectroscopy (SERS) detection.

Keywords:
SERSSERS substrateschemical sensinglab-on-a-chipmicrofluidicsplasmonicpolymer injection molding

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Area of Science:

  • Materials Science
  • Nanotechnology
  • Analytical Chemistry

Background:

  • Affordable and mass-producible miniaturized sensing platforms are crucial for widespread diagnostic applications.
  • Existing methods often face challenges in cost-effectiveness and scalability for integrated sensing systems.

Purpose of the Study:

  • To present a fully polymeric microfluidic lab-on-a-chip device with integrated gold (Au)-capped nanocones for surface-enhanced Raman spectroscopy (SERS) sensing.
  • To demonstrate a cost-effective, reproducible, and scalable fabrication method for high-performance SERS sensors.

Main Methods:

  • Fabrication of polymeric microfluidic device components using injection molding (IM).
  • Integration of components via ultrasonic welding.
  • Creation of SERS active nanostructures by evaporating Au onto IM nanocone structures.

Main Results:

  • Achieved a surface-averaged SERS enhancement factor of approximately 5 × 106.
  • Demonstrated good reproducibility with a relative standard deviation of 14% over the sensor area and 18% signal variation among substrates.
  • Fabricated densely packed Au-capped SERS active nanostructures with high density and high aspect ratio.

Conclusions:

  • The developed fabrication method is cost-effective, time-efficient, and suitable for mass production.
  • The fully polymeric microfluidic SERS device offers a promising platform for affordable and sensitive detection.
  • This technology enables the development of integrated, miniaturized sensing systems for various diagnostic applications.