Micromilling of Poly(methyl methacrylate, PMMA) Using Single-Crystal Diamond Tools

An Alternative Micro-Milling Fabrication Process for Rapid and Low-Cost Microfluidics

Microfluidics is an important technology for the biomedical industry and is often utilised in our daily lives. Recent advances in micro-milling technology have allowed for rapid fabrication of smaller and more complex structures, at lower costs, making it a viable alternative to other fabrication methods. The microfluidic chip fabrication developed in this research is a step-by-step process with a self-contained wet milling chamber. Additionally, ethanol solvent bonding is used to allow microfluidic chips to be fully fabricated within approximately an hour. The effect of using this process is tested with quantitative contact profileometery data to determine the expected surface roughness in the microchannels. The effect of surface roughness on the controllability of microparticles is tested in functional microfluidic chips using image processing to calculate particle velocity. This process can produce high-quality channels when compared with similar studies in the literature and surface roughness affects the control of microparticles. Lastly, we discuss how the outcomes of this research can produce rapid and higher-quality microfluidic devices, leading to improvement in the research and development process within the fields of science that utilise microfluidic technology. Such as medicine, biology, chemistry, ecology, and aerospace.

Current and Future Trends for Polymer Micro/Nanoprocessing in Industrial Applications

Polymers are widely used in optical devices, electronic devices, energy-harvesting/storage devices, and sensors, owing to their low weight, excellent flexibility, and simple fabrication process. With advancements in micro/nanoprocessing techniques and more demanding application requirements, it is becoming necessary to realize high-resolution fabrication of polymers to prepare miniaturized devices. This is particularly because conventional processing technologies suffer from high thermal stress and strong adhesion/friction, which can irreversibly damage the micro/nanostructures of miniaturized devices. In addition, although the use of advanced fabrication methods to prepare high-resolution micro/nanostructures is explored, these methods are limited to laboratory research or small-batch production. This review focuses on the micro/nanoprocessing of polymeric materials and devices with high spatial precision and replication accuracy for industrial applications. Specifically, the current state-of-the-art techniques and future trends for micro/nanomolding, high-energy beam processing, and micro/nanomachining are discussed. Moreover, an overview of the fabrication and applications of various polymer-based elements and devices such as microlenses, biosensors, and transistors is provided. These techniques are expected to be widely applied for multiscale and multimaterial processing as well as for multifunction integration in next-generation integrated devices, such as photoelectric, smart, and biodegradable devices.

A Systematic Approach for Developing 3D High-Quality PDMS Microfluidic Chips Based on Micromilling Technology

In recent years, there has been an increased interest in exploring the potential of micro-and mesoscale milling technologies for developing cost-effective microfluidic systems with high design flexibility and a rapid microfabrication process that does not require a cleanroom. Nevertheless, the number of current studies aiming to fully understand and establish the benefits of this technique in developing high-quality microsystems with simple integrability is still limited. In the first part of this study, we define a systematic and adaptable strategy for developing high-quality poly(methyl methacrylate) (PMMA)-based micromilled structures. A case study of the average surface roughness (Ra) minimization of a cuboid column is presented to better illustrate some of the developed strategies. In this example, the Ra of a cuboid column was reduced from 1.68 μm to 0.223 μm by implementing milling optimization and postprocessing steps. In the second part of this paper, new strategies for developing a 3D microsystem were introduced by using a specifically designed negative PMMA master mold for polydimethylsiloxane (PDMS) double-casting prototyping. The reported results in this study demonstrate the robustness of the proposed approach for developing microfluidic structures with high surface quality and structural integrability in a reasonable amount of time.

Orientation of Liquid Crystalline Molecules on PDMS Surfaces and within PDMS Microfluidic Systems

The unique components of PDMS-based microfluidic systems are those combined with liquid crystalline materials. Their functionality, especially when it comes to optical applications, highly depends on the LC molecular arrangement. This work summarizes experimental investigations on the orientation of molecules within LC:PDMS structures according to the manufacturing technologies. The availability of high-quality molds to pattern PDMS is a significant barrier to the creation of advanced microfluidic systems. The possibility of using inexpensive molds in the rapid and reproducible fabrication process has been particularly examined as an alternative to photolithography. Different geometries, including an innovative approach for the electrical control of the molecular arrangement within PDMS microchannels, are presented. These studies are critical for novel optofluidic systems, introducing further research on LC:PDMS waveguiding structures.

Fabrication and characterization of resistive double square loop arrays for ultra-wide bandwidth microwave absorption

Microwave absorbers using conductive ink are generally fabricated by printing an array pattern on a substrate to generate electromagnetic fields. However, screen printing processes are difficult to vary the sheet resistance values for different regions of the pattern on the same layer, because the printing process deposits materials at the same height over the entire surface of substrate. In this study, a promising manufacturing process was suggested for engraved resistive double square loop arrays with ultra-wide bandwidth microwave. The developed manufacturing process consists of a micro-end-milling, inking, and planing processes. A 144-number of double square loop array was precisely machined on a polymethyl methacrylate workpiece with the micro-end-milling process. After engraving array structures, the machined surface was completely covered with the developed conductive carbon ink with a sheet resistance of 15 Ω/sq. It was cured at room temperature. Excluding the ink that filled the machined double square loop array, overflowed ink was removed with the planing process to achieve full filled and isolated resistive array patterns. The fabricated microwave absorber showed a small radar cross-section with reflectance less than − 10 dB in the frequency band range of 8.0–14.6 GHz.

Thermal Effect on Poly(methyl methacrylate) (PMMA) Material Removal in the Micromilling Process

Poly(methyl methacrylate) (PMMA) is of growing interest in the application of microfluidic devices and high precision optical elements due to its excellent moldability and formability. Micromilling is one of the micromachining methods which has been extensively used to manufacture polymer components. In this study, a high-speed micromilling method was used to manufacture polymer with high form accuracy and surface quality. The processing temperature effects on the surface quality were investigated in detail. The dynamic mechanical analysis (DMA) experiment was used to study the material mechanical property under different temperatures. According to the DMA results, the PMMA sample is in the glass and viscoelastic state during the milling process. The cutting chips under various processing temperatures are classified into three kinds according to their shapes: roll, sheet, and sinter. The surface roughness of samples with sheet and roll cutting chips is smaller than that of sinter cutting chips. To obtain a better machining bottom surface and edge shape, the processing temperature below 70 °C is recommended according to the results. This work is of great value for the study of polymer removal mechanism and optimization of processing parameters for the industry.