We demonstrated rapid prototyping of templates for replica molding using a conventional laser printer. A polymer, polydimethylsiloxane, was cast directly on the transparency templates to make the replicas. The templates and replicas were characterized by scanning electron microscopy, profilometry, and optical microscopy. Four patterns, including an Electronic Industries Association resolution test pattern, were printed on transparencies at 600 dots per inch on a HP LaserJet 4M printer (Hewlett-Packard, Palo Alto, CA). Optimal precision and clarity occurred between intensity settings of 50-100. Mean pattern height/depth ranged from 8-13 m, and width was as small as a few tenths of a millimeter. Mean surface roughness of the template patterns ranged from 1 to 4 m on the top surface and from 5 to 10 nm on the bare transparency surface. This method provides access to microfabricated patterns for the broader research community without the need for sophisticated micromachining facilities.The interest in miniaturized systems for biochemical analysis and biomedical research continues to grow rapidly. Devices commonly referred to as micro total analytical systems (TAS) have been reported for a diverse range of applications, such as the determination of monoclonal antibodies, 1 the determination of phosphate 2 and nitrite, 3 and for high-speed DNA sequencing. 4 The application of similar devices to cell culture and cell mechanics 5 is also expanding to include the geometric control of cell shape, 6 orientation, and gene expression, 7 as well as the adhesion of neurons 8 and growth cone guidance. 9 The devices themselves usually require photolithographic microfabrication techniques to produce them since conventional machining will not provide sufficiently small devices (colloquially referred to as chips). A review by Madou provides information relating to all aspects of microfabrication. 10 Chip-based devices manufactured from glass are perhaps the most widely used in part because of the versatility and chemical resistivity of glass, the relatively straightforward fabrication, and the ease of optical detection in glass devices. However, a major problem frequently encountered by researchers without specialized facilities is how to produce prototype devices rapidly and at a realistic cost. This paper describes a practical method for the fabrication of templates, stamps, or molds using a laser printer with resolution of 600 dots per inch (dpi) or greater and solvent-free transparency film as a substrate (Fig. 1). The overall time from a computer design to a micropatterned surface is 14-24 h, most of which is for curing the polymer. No access to spin coaters, ultraviolet radiation, or tools normally found in the semiconductor process is
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