Review on ultrasonic fabrication of polymer micro devices

Sackmann, Johannes; Burlage, Katharina; Gerhardy, C.; Memering, B.; Liao, Shaowei; Schomburg, Werner Karl

doi:10.1016/j.ultras.2014.08.007

Cited by 87 publications

(53 citation statements)

References 36 publications

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“…Ultrasonic welding (UW) [1,13,14] is an extremely appealing technique for the bonding of polymers, since it is fast (a few seconds per sample), and since localized UW eliminates the need for potentially hazardous solvents and high temperatures. For these reasons, UW is compatible with the pre-loading of temperature-sensitive materials or even of biological material, such as DNA [15].…”

Section: Introductionmentioning

confidence: 99%

“…The ultrasound energy makes the energy directors melt, allowing bonding of the two parts (Figure 1a,b). It was demonstrated that UW is a very useful tool for both self-aligned gapless welding of polymer chips and for sealing of low-aspect ratio, large-area microchannels [1,13,14,16,21,22]. Here, we focus on the use of UW for the integration of embedded metal electrodes in injection molded (IM) microfluidic chips (Figure 1b,c) made of cyclic olefin copolymer (COC).…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Comparison of Ultrasonic Welding and Thermal Bonding for the Integration of Thin Film Metal Electrodes in Injection Molded Polymeric Lab-on-Chip Systems for Electrochemistry

Matteucci¹,

Heiskanen²,

Zór³

et al. 2016

Sensors

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We compare ultrasonic welding (UW) and thermal bonding (TB) for the integration of embedded thin-film gold electrodes for electrochemical applications in injection molded (IM) microfluidic chips. The UW bonded chips showed a significantly superior electrochemical performance compared to the ones obtained using TB. Parameters such as metal thickness of electrodes, depth of electrode embedding, delivered power, and height of energy directors (for UW), as well as pressure and temperature (for TB), were systematically studied to evaluate the two bonding methods and requirements for optimal electrochemical performance. The presented technology is intended for easy and effective integration of polymeric Lab-on-Chip systems to encourage their use in research, commercialization and education.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Comparison of Ultrasonic Welding and Thermal Bonding for the Integration of Thin Film Metal Electrodes in Injection Molded Polymeric Lab-on-Chip Systems for Electrochemistry

Matteucci¹,

Heiskanen²,

Zór³

et al. 2016

Sensors

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“…Table 1 summarizes the set processing parameters. Ultrasonic energy generated within the ultrasonic welding process has been used in industrial applications such as welding, deforming and joining of thermoplastic polymer materials for more than six decades [5,6]. However, in the field of composite materials, ongoing research activities focus on employing the ultrasonic welding process for the joining of CFRP parts, which were fabricated by industrial state of the art fabrication processes such as pultrusion, winding, processing of prepregs or resin transfer moulding (RTM).…”

Section: Machinesmentioning

confidence: 99%

“…The cycle time of this process is only a few seconds and the required investment costs are on the order of some 10,000 €. Because of the local heating of the material, ultrasonic processing is relatively low energy consuming and various thermoplastic polymers as well as various ultrasonic processing is relatively low energy consuming and various thermoplastic polymers as well as various fiber materials can be processed [5,6]. Figure 1 describes schematically how CFRP has been fabricated by ultrasonic welding.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Fiber Reinforced Plastics by Ultrasonic Welding

et al. 2018

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Ultrasonic fabrication of fiber reinforced plastics made from thermoplastic polymer films and carbon or glass fibers enables cycle times of a few seconds and requires investment costs of only some 10,000 €. Besides this, the raw materials can be stored at room temperature. A fiber content of 33 vol % and a tensile strength of approximately 1.2 GPa have been achieved by ultrasonic welding of nine layers of foils from polyamide, each 100 µm in thickness, and eight layers of carbon fibers, each 100 µm in thickness, in between. Besides unidirectional carbon fiber reinforced polymer composite (CFRP) samples, multi-directional CFRP plates, 116 mm, 64 mm and 1.2 mm in length, width and thickness respectively, were fabricated by processing three layers of carbon fiber canvas, each 300 µm in thickness, and eight layers of polyamide foils, each 100 µm in thickness. Furthermore, both the discontinuous and the continuous ultrasonic fabrication processes are described and the results are presented in this paper. Large-scale production still needs to be demonstrated.

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“…For polymers, rapid fabrication of single reactors is possible by replication techniques such as injection molding or hot embossing [7][8][9][10]. Hot embossing facilitates a cheap fabrication of nearly any desired structures [11], furthermore improved by the implementation of ultrasound [12,13].…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic Hot Embossed Polymer Microreactors for Optical Measurement of Chemical Reactions

et al. 2014

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Ultrasonic hot embossing of polymers is an alternative to reduce fabrication costs of microreactors. An ultrasonic welding machine is used to melt a stack of thermoplastic foils and adapting them to a short-time milled aluminum mold showing the inversed design of the desired microfluidic cavities. Two micromixers were fabricated this way providing a low degree of axial dispersion and pressure loss. Stability analysis is successfully performed for a wide temperature range and high pressure. Mixing of colored aqueous solutions and neutralization reactions are implemented to both systems for defined volume flow rates and optically investigated via microscope. Reaction progress is automatically determined with a MATLAB script by reference to the consequential color change of the neutralization reaction with a color indicator. Typical mixing characteristics are identified for both mixers.

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Review on ultrasonic fabrication of polymer micro devices

Cited by 87 publications

References 36 publications

Comparison of Ultrasonic Welding and Thermal Bonding for the Integration of Thin Film Metal Electrodes in Injection Molded Polymeric Lab-on-Chip Systems for Electrochemistry

Comparison of Ultrasonic Welding and Thermal Bonding for the Integration of Thin Film Metal Electrodes in Injection Molded Polymeric Lab-on-Chip Systems for Electrochemistry

Fabrication of Fiber Reinforced Plastics by Ultrasonic Welding

Ultrasonic Hot Embossed Polymer Microreactors for Optical Measurement of Chemical Reactions

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