3D Printing of Metallic Microstructured Mould Using Selective Laser Melting for Injection Moulding of Plastic Microfluidic Devices

Abstract

A new method, a 3D printing technique, in particular, selective laser melting (SLM), has been used to fabricate moulds for the injection moulding of thermoplastic microfluidic chips that are suitable for prototyping and early stage scale-up. The micro metallic patterns are printed on to a pre-finished substrate to form a microstructured mould. The dimensional accuracy, surface morphology, bonding strength between the printed patterns and substrate, as well as the microstructure of micro features were all characterized. A microfluidic mould was successfully printed and used directly for injection moulding of cyclic olefin copolymer (COC) microfluidic chips, which were used subsequently to successfully monitor nitrite concentrations in environmental water. The characterization indicated that this new process can be used for fast fabrication of mould tools for injection moulding/hot embossing microfluidic devices. It is faster, more flexible and less expensive than conventional micro-machining processes, although the accuracy and finish are still needed to improve though process optimization and hybrid SLM and machining processes.

Recent Progress in 3D Printed Mold-Based Sensors

“…One of the interesting works in this area involves the use of metallic micro-structured molds to develop plastic microfluidic devices [69]. The 3D printing technique used to develop these metallic micro-structures molds was a selective laser sintering method.…”

“…Other advantages provided by this technique were cost-effectiveness, flexibility in the customization of the design of the device, and high quality in the finishing of the prototypes. One of the interesting works in this area involves the use of metallic micro-structured molds to develop plastic microfluidic devices [69]. The 3D printing technique used to develop these metallic micro-structures molds was a selective laser sintering method.…”

Characterization and Evaluation of 3D-Printed Connectors for Microfluidics

“…With the coming of a new era in additive manufacturing [ 12 , 13 , 14 , 15 , 16 ], 3D printing provides convenience and design flexibility to the fabrication of microfluidic interconnections. These 3D-printed connectors can be either simultaneously printed fluid ports on 3D-printed microfluidic chips [ 17 , 18 ] or separated adapters fixed on microfluidic devices [ 19 , 20 , 21 ].…”

Theoretical and Experimental Study on Hot-Embossing of Glass-Microprism Array without Online Cooling Process

“…Picosecond laser micromachining was used to fabricate a microcircular hole array on the steel die-core surface, but its machining accuracy was unknown [15]. The accuracy of the selective laser melting manufacturing of a metallic microstructured core was studied, but it had dimensional deviation [16]. Focused-ion-beam milling could produce high-surface-quality microstructures, but it had low processing efficiency [17].…”