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Updated: Oct 20, 2025

Fabrication of the Thermoplastic Microfluidic Channels
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Fabrication of the Thermoplastic Microfluidic Channels

Published on: February 3, 2008

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Thermoplastic Microfluidics.

Per Magnus Kristiansen1,2,3, Agnieszka Karpik4,5, Jerome Werder4

  • 1FHNW University of Applied Sciences and Arts Northwestern Switzerland, School of Engineering, Institute of Polymer Nanotechnology (INKA), Windisch, Switzerland. magnus.kristiansen@fhnw.ch.

Methods in Molecular Biology (Clifton, N.J.)
|September 14, 2021
PubMed
Summary
This summary is machine-generated.

Switching from polydimethylsiloxane (PDMS) to thermoplastic polymers like cyclo-olefin (co)polymer (COC, COP) early in microfluidic device development is crucial for industrialization. This enables addressing manufacturing challenges and optimizing production processes for organ-on-chip applications.

Keywords:
2-photon polymerizationHot embossingInjection moldingLaser micromachining

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Area of Science:

  • Materials Science
  • Microfluidics Engineering

Background:

  • Thermoplastic polymers and glass are preferred for microfluidic and organ-on-chip applications.
  • Current development often relies on polydimethylsiloxane (PDMS) using lithography, neglecting industrialization aspects.
  • Early transition to thermoplastic polymers like cyclo-olefin (co)polymer (COC, COP) is vital for scalable manufacturing.

Purpose of the Study:

  • To present a standard process for microfluidic device fabrication using two-photon polymerization and hot embossing into COC.
  • To describe laser micromachining for polymeric mold inserts.
  • To detail prototype injection molding of cyclo-olefin polymer (COP) samples for small series production.

Main Methods:

  • Two-photon polymerization for microfluidic device mastering.
  • Hot embossing for transferring designs into cyclo-olefin (co)polymer (COC) films.
  • Laser micromachining for creating polymeric mold inserts.
  • Prototype injection molding for cyclo-olefin polymer (COP) sample fabrication.

Main Results:

  • A defined process sequence for microfluidic device fabrication in COC was established.
  • Successful laser micromachining of mold inserts was achieved.
  • Prototype injection molding of COP samples was demonstrated for small-scale production.

Conclusions:

  • Early adoption of thermoplastic polymers like COC/COP facilitates identification and resolution of industrialization challenges in microfluidics.
  • The presented methods enable efficient prototyping and small-series manufacturing of microfluidic devices.
  • This approach supports the transition from laboratory-scale development to industrial production of organ-on-chip technologies.