Flexible Inserts for Injection Molding of Complex Micro‐Structured Polymer Components

Mass production of microfluidic devices commonly relies on injection molding. Injection molding requires a master surface made using micro or nanofabrication. Conventionally, electroplating from silicon is used for mold insert production, but this expensive and cannot be with masters produced via the Bosch process as interlocking scalloping between polymer metal hinders part ejection. Here, an alternative to developed by adapting nanoimprint route produce flexible micro-structured inserts capable process-produced master. An optimized fabrication approach smooth sidewalls (produced mixed process) characterize limits process. Aspect ratios 1 below are successfully replicated. Feature spacings down 20 µm minimal variation repeated parts. Masters two different etches exhibiting both coarse fine nanometer also studied. Parts ejected retained in all samples although inlay damage occurred after >10 replicas. A proof-of-concept device vindicating use efficient cost-effective rapid prototyping complex designs.