4.4 Article

Manufacturing microstructured tool inserts for the production of polymeric microfluidic devices

Journal

Publisher

IOP PUBLISHING LTD
DOI: 10.1088/0960-1317/25/9/095005

Keywords

bulk metallic glass (BMG); nickel insert; stainless steel tooling

Funding

  1. Enterprise Ireland [CFTD/07/314, CF/2012/2022, CF/2012/2640B]
  2. European Regional Development Fund

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Tooling is critical in defining multi-scale patterns for mass production of polymeric microfluidic devices using the microinjection molding process. In the present work, fabrication of various microstructured tool inserts using stainless steel, nickel and bulk metallic glasses (BMGs) is discussed based on die-sinking EDM (electrical discharge machining), electroforming, focused ion beam milling and thermoplastic forming processes. Tool performance is evaluated in terms of surface roughness, hardness and tool life. Compared to stainless steel, nickel and BMGs are capable of integrating length scales from 10(0) to 10(-8) m and are good candidates for producing polymeric microfluidics. Selection of tool materials and manufacturing technologies should consider the end-user requirements of actual applications.

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