Characterization of Microchannel Replicability of Injection Molded Electrophoresis Microfluidic Chips

Effect of Interfacial Interaction on the Demolding Deformation of Injection Molded Microfluidic Chips

During the demolding process, the interfacial interaction between the polymer and the metal mold insert will lead to the deformation of the micro-structure, which will directly affect the molding quality and performance of injection molded microfluidic chips. In this study, the demolding quality of micro-channels and micro-mixing structures of polycarbonate (PC), polymethyl methacrylate (PMMA), cyclic olefin copolymer (COC), and polystyrene (PS) microfluidic chips for heavy metal detection were investigated by molding experiments. The experimental results showed that the structures of microfluidic chips could be completely replicated. However, tensile deformation and fracture defects were observed at the edges of the micro-structures after demolding. Compared to the Ni mold insert, the calculation of the relative deviation percentages showed that the width of the micro-channel became larger and the depth became smaller, while the dimensions of the micro-mixing structure changes in the opposite direction. Subsequently, a molecular dynamics (MD) simulation model of polymer/nickel (Ni) mold insert for injection molding was established. The changes of adhesion work, demolding resistance and potential energy during demolding were analyzed. The simulation results showed that the polymer structures had some deformations such as necking, molecular chain stretching and voids under the action of adhesion work and demolding resistance. The difference in the contact area with the mold insert directly brought different interfacial interactions. In addition, the potential energy change of the polymer system could be used to quantitatively characterize the demolding deformation of the structure. Overall, the MD method is able to effectively explain the internal mechanisms of interfacial interactions, leading to the demolding deformation of polymer structures from the molecular/atomic scale.

A new fuzzy rule based multi-objective optimization method for cross-scale injection molding of protein electrophoresis microfluidic chips

Injection molding is one of the most promising technologies for the large-scale production and application of polymeric microfluidic chips. The multi-objective optimization of injection molding process for substrate and cover plate on protein electrophoresis microfluidic chip is performed to solve the problem that the forming precision is difficult to coordinate because of the cross-scale structure characteristics for chip in this paper. The innovation for this research is that an optimization approach and a detailed fuzzy rule determination method are proposed in multi-objective optimization for protein electrophoresis microfluidic chip. In more detail, firstly, according to the number and level of process parameters, the orthogonal experimental design is carried out. Then, the experiments are performed. Secondly, the grey relational analysis (GRA) approach is employed to process the response data to gain the grey relational coefficient (GRC). Thirdly, the grey fuzzy decision making method which combines triangular membership function and gaussian membership function is adopted to obtain the grey fuzzy grade (GFG). After that, the optimal scheme of process parameters was predicted by the grey fuzzy grade analysis. Finally, the superiority of Taguchi grey fuzzy decision making method are verified by comparing the results of original scheme, optimal scheme and prediction scheme. As a result, compared with the original design, the residual stress of substrate plate (RSS), residual stress of cover plate (RSC), warpage of substrate plate (WS), warpage of cover plate (WC) and replication fidelity of microchannel for substrate plate (RFM) on the prediction scheme for Taguchi grey fuzzy decision making method were reduced by 32.816%, 29.977%, 88.571%, 74.390% and 46.453%, respectively.

2D Spatially-Resolved Depth-Section Microfluidic Flow Velocimetry Using Dual Beam OCT

A dual beam optical coherence tomography (OCT) instrument has been developed for flow measurement that offers advantages over microscope derived imaging techniques. It requires only a single optical access port, allows simultaneous imaging of the microfluidic channel, does not require fluorescent seed particles, and can provide a millimetre-deep depth-section velocity profile (as opposed to horizontal-section). The dual beam instrument performs rapid re-sampling of particle positions, allowing measurement of faster flows. In this paper, we develop the methods and processes necessary to make 2D quantitative measurements of the flow-velocity using dual beam OCT and present exemplar results in a microfluidic chip. A 2D reference measurement of the Poiseuille flow in a microfluidic channel is presented over a spanwise depth range of 700 μm and streamwise length of 1600 μm with a spatial resolution of 10 μm, at velocities up to 50 mm/s. A measurement of a more complex flow field is also demonstrated in a sloped microfluidic section.

Efficient and Precise Micro-Injection Molding of Micro-Structured Polymer Parts Using Micro-Machined Mold Core by WEDM

In this paper, micro-structured polymer parts were efficiently and accurately fabricated by micro-injection molding using a micro-structured mold core machined by wire electrical discharge machining (WEDM). The objective was to realize low-cost mass production and manufacturing of micro-structured polymer products. The regular micro-structured mold core was manufactured by precise WEDM. The micro-structured polymer workpieces were rapidly fabricated by micro-injection molding and the effects of the micro-injection molding process parameters on replication rate and surface roughness of micro-structured polymers were systematically investigated and analyzed. It is shown that the micro-structured polymer can be rapidly and precisely fabricated by the proposed method. The experimental results show the minimum size machining error of the micro-structured mold core and the maximum replication rate of micro-formed polymer were 0.394% and 99.12%, respectively. Meanwhile, the optimal micro-injection molding parameters, namely, jet temperature, melt temperature, injection velocity, holding pressure and holding time were 195 °C, 210 °C, 40 mm/min, 7 Mpa and 5 s, respectively. The surface roughness R_a at the groove bottom and top of the micro-structured polymer workpieces achieved minimum values of 0.805 µm and 0.972 µm, respectively.