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Sensors 2016, 16(12), 2023;

One-Step Fabrication of Microchannels with Integrated Three Dimensional Features by Hot Intrusion Embossing

Department of Chemistry, University of Toronto, Toronto, ON M5S 3H6, Canada
FlowJEM Inc., Toronto, ON M5S 3H6, Canada
Département de Chimie, Université Laval, Québec, QC G1V 0A6, Canada
Department of Chemistry, University of Eastern Finland, Joensuu FI-80101, Finland
Author to whom correspondence should be addressed.
Academic Editor: Vittorio M. N. Passaro
Received: 23 September 2016 / Revised: 15 November 2016 / Accepted: 22 November 2016 / Published: 29 November 2016
(This article belongs to the Special Issue Microfluidics-Based Microsystem Integration Research)
Full-Text   |   PDF [3471 KB, uploaded 29 November 2016]   |  


We build on the concept of hot intrusion embossing to develop a one-step fabrication method for thermoplastic microfluidic channels containing integrated three-dimensional features. This was accomplished with simple, rapid-to-fabricate imprint templates containing microcavities that locally control the intrusion of heated thermoplastic based on their cross-sectional geometries. The use of circular, rectangular and triangular cavity geometries was demonstrated for the purposes of forming posts, multi-focal length microlense arrays, walls, steps, tapered features and three-dimensional serpentine microchannels. Process variables, such as temperature and pressure, controlled feature dimensions without affecting the overall microchannel geometry. The approach was demonstrated for polycarbonate, cycloolefin copolymer and polystyrene, but in principle is applicable to any thermoplastic. The approach is a step forward towards rapid fabrication of complex, robust, microfluidic platforms with integrated multi-functional elements. View Full-Text
Keywords: microfluidics; microfabrication; thermoplastic; hot embossing; intrusion embossing microfluidics; microfabrication; thermoplastic; hot embossing; intrusion embossing

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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).

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Debono, M.; Voicu, D.; Pousti, M.; Safdar, M.; Young, R.; Kumacheva, E.; Greener, J. One-Step Fabrication of Microchannels with Integrated Three Dimensional Features by Hot Intrusion Embossing. Sensors 2016, 16, 2023.

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