Fabrication of thermoset polyester microfluidic devices and embossing masters using rapid prototyped polydimethylsiloxane molds

Abstract

Plastics are increasingly being used for the fabrication of Lab-on-a-Chip devices due to the variety of beneficial material properties, affordable cost, and straightforward fabrication methods available from a range of different types of plastics. Rapid prototyping of polydimethylsiloxane (PDMS) devices has become a well-known process for the quick and easy fabrication of microfluidic devices in the research laboratory; however, PDMS is not always an appropriate material for every application. This paper describes the fabrication of thermoset polyester microfluidic devices and masters for hot embossing using replica molding techniques. Rapid prototyped PDMS molds are convienently used for the production of non-PDMS polymeric devices. The recessed features in the cast polyester can be bonded to a second polyester piece to form an enclosed microchannel. Thermoset polyester can withstand moderate amounts of pressure and elevated temperature; therefore, the cast polyester piece also can be used as a master for embossing polymethylmethacrylate (PMMA) microfluidic systems. Examples of enclosed polyester and PMMA microchannels are presented, and we discuss the electroosmotic properties of both types of channels, which are important for analytical applications such as capillary electrophoresis.

Thermoset polyester as an alternative material for microchip electrophoresis/electrochemistry

“…TPE has been reported previously in three separate publications [41,42,48]. In the previous work, EOF was measured for only five days.…”

“…The process of fabricating TPE as a microfluidic device has been described previously by Fiorini et al [41,42]. With fabrication techniques similar to PDMS, little to no modification to existing soft lithography techniques are needed [43,44].…”

Fabrication, modification, and application of poly(methyl methacrylate) microfluidic chips

“…The analytical performance of their microchip system was demonstrated by electrophoretic separations of dsDNA ladders (fX174 digested with HaeIII) with satisfactory results. Fiorini et al [16] have fabricated thermoset polyester masters for hot embossing. Rapid prototyped PDMS molds were conveniently used for the production of non-PDMS polymeric devices.…”

In‐channel atom‐transfer radical polymerization of thermoset polyester microfluidic devices for bioanalytical applications

“…One such polymer is thermoset polyester (TPE), which has been introduced previously for the fabrication of microfluidic devices [14,15]. Importantly, TPE microchips combine the benefits of rapid and easy fabrication along with several desirable characteristics in common with glass.…”