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Nowadays, the prototypes of microfluidic systems are generally produced via micromilling of thermoplastic polymethyl methacrylate (PMMA). The main limitations are the design of micro tools with diameters D ≤ 50 μm adapted for each application, and the understanding of the machining process itself. The objective of this research work is to contribute to mastering the process of PMMA micromilling with tool diameters D ≤ 50 μm on a 3-axes precision milling machine. For this purpose, the process design must include the complete process chain-from the CAD/CAM data up to the final structure geometry. The main requirements are the manufacture of microfluidic structures with R a < 60 nm on the groove bottom and a top burr overhang h 0 < 3 μm. Based on the experimental results, milling parameters were established and the influence of the tool geometry on the burr formation was determined. Finally, CAD/CAM machining strategies were recommended.Keywords Micromachining . Micromilling . Lab-on-chip . Ultra-small micro end mill

Plain and microstructured cp-titanium samples were studied as possible biofilm reactor substrates. The biofilms were grown by exposition of the titanium samples to bacteria in a flow cell. As bacteria the rod shaped gram negative Pseudomonas fluorescens and the spherical gram negative Paracoccus seriniphilus were chosen. Afterward, the samples were cleaned in subsequent steps: First, with a standard solvent based cleaning procedure with acetone, isopropanol, and ultrapure water and second by oxygen plasma sputtering. It will be demonstrated by means of x-ray photoelectron spectroscopy, fluorescence microscopy, and confocal laser scanning microscopy that oxygen plasma cleaning is a necessary and reliant tool to fully clean and restore titanium surfaces contaminated with a biofilm. The microstructured surfaces act beneficial to biofilm growth, while still being fully restorable after biofilm contamination. Scanning electron microscopy images additionally show, that the plasma process does not affect the microstructures. The presented data show the importance of the cleaning procedure. Just using solvents does not remove the biofilm and all its components reliably while a cleaning process by oxygen plasma regenerates the surfaces.

Current demands for flexible, individual microstructures in high quality result in high requirements for micro tools. As the tool size defines the minimum structure size, ultra-small tools are needed. To achieve tool diameters of 50 µm and lower, we investigate the complete manufacturing chain of micro machining. From the development of the machine tools and components needed to produce and apply the micro tools, the micro tools themselves, as well as the micro machining processes. Machine tools are developed with the possibility of producing the micro geometry (cutting edge design) of micro tools as well as plating processes to produce super abrasive micro grinding tools. Applying these setups, we are able to produce ultra-small micro grinding and micro milling tools with typical diameters of 50 µm and down to 4 µm. However, the application of such tools is very challenging. The article presents possibilities and limitations in manufacturing the micro tools themselves as well as microstructures made with these tools. A special emphasis will be on the influence of the tool substrate in micro milling and grain sizes in micro grinding.

The bacterial attachment to surfaces is the first step of biofilm formation. This attachment is governed by adhesion forces which act between the bacterium and the substrate. Such forces can be measured by single cell force spectroscopy, where a single bacterium is attached to a cantilever of a scanning force microscope, and force-distance curves are measured. For the productive sea-water bacterium Paracoccus seriniphilus, pH dependent measurements reveal the highest adhesion forces at pH 4. Adhesion forces measured at salinities between 0% and 4.5% NaCl are in general higher for higher salinity. However, there is an exception for 0.9% where a higher adhesion force was measured than expected. These results are in line with zeta potential measurements of the bacterium, which also show an exceptionally low zeta potential at 0.9% NaCl. In the absence of macromolecular interactions, the adhesion forces are thus governed by (unspecific) electrostatic interactions, which can be adjusted by pH and ionic strength. It is further shown that microstructures on the titanium surface increase the adhesion force. Growth medium reduces the interaction forces dramatically, most probably through macromolecular bridging.

Microorganisms growing in biofilms might be possible biocatalysts for future biotechnological production processes. Attached to a surface and embedded in an extracellular polymeric matrix, they create their preferred environment and form robust cultures for continuous systems. With the objective of implementing highly efficient processes, productive biofilms need to be understood comprehensively. In this study, the influence of microstructured metallic surfaces on biofilm productivity was researched. To conduct this study, titanium and stainless steel sheets were polished, micromilled, as well as coated with particles. Subsequently, the metal sheets were exposed to the lactic acid producing Lactobacillus delbrueckii subsp. lactis under laminar and homogeneous flow conditions in a custom-built flow cell. A proof-ofconcept showed that biofilm formation in the system only occurred on the designated substratum. Following a 24-h batch cultivation for primary biofilm development, the culture was continuously provided with glucose containing medium. As different experimental series have indicated, the process resulted to be stable for up to eleven days. Primary metabolite productivity averaged around 6-7 g/(L h). Interestingly, the productivity was shown to be affected neither by the type of metal, nor by the applied microstructures. Nevertheless, a higher dry biomass weight determined on micro-milled substratum indicates a complementary differentiation of biofilm components in future experiments.

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Micro hardness determination on rough surfaces is a topic of interest e.g. in industrial applications where the component surface is of functional relevance. In most approaches, hardness on a rough surface is determined by including profile roughness parameters like R a (e.g., [1][2][3][4][5]) to adjust measured hardness values or to get the minimum indentation depth value where the influence of the surface topography is assumed to become negligibly small. In the present study, local surface topography data were used instead to enable precise micro hardness measurements on a sample with arbitrary surface topography. Samples made of 1.457 1 stainless steel with different surface states were face milled by using an end mill with different feed rates. Instrumented indentation tests were performed on these samples as well as on comparative samples with polished surfaces. From the resulting load-indentation depth (F-d)-curves the averaged indentation hardness was calculated for all surface states. A method was applied to manipulate and to average the F-d-curves to eliminate deviations, occurring at the beginning of the indentation. The indentation hardness was calculated from these modified F-d-curves and compared to the indentation hardness from the actually measured F-d-curves of the polished samples with feasible results. Using surface topography measurements is considered to enable deriving more accurate indentation hardness values directly and to put the investigations to another level. The surface topography of the samples was evaluated by confocal microscope measurements before and after the indentation tests. From the surface topography data at the location of indentation, four parameters were calculated: volume, projected contact area and depth of the indentation mark, as well as the curvature of the surface topography before indentation. These parameters were correlated with the hardness value from the respective indentation and compared to the indentation hardness of the polished sample. The results of the present study are the basis for combining optical imaging techniques like confocal microscopy or white light interferometry and indentation testing equipment to broaden the field of application.