New microfluidic functionalities by nano- and micro-patterned moulds

FaBiMed is a European project established to develop new manufacturing strategies for medical micro devices, using polymer replication in production of cost effective miniaturized micro and nanostructured components in biocompatible and functional materials. One demonstration line is dedicated to compact disposable lab-on-chip devices and requires micro and nano]structuring of the mould surface in order to change wetting characteristics of microfabricated devices and enable them with additional microfluidic functional features such as micro-channels or cell filters. Such features must be effectively replicated by hot]embossing (HE) or microinjection moulding (IM), at the same time avoiding time]dependent clogging by residual polymer, after multiple replication cycles. The paper describes the mould manufacturing process combining four sequential technologies as well as the replication results.