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This paper presents the adaptation of a conventional injection moulding process to manufacture microfluidic components in thermoplastic polymers using alternative, exchangeable microstructured silicon-based mould inserts. The mould inserts consist of thick silicon wafers with microfeatures patterned in SU-8 epoxy photo-resist. This process allows changing the mould inserts according to the design, very easily and cost-effectively. The SU-8/Si mould inserts were robust enough to manufacture small series for laboratory purpose. More than a hundred replicas in thin polypropylene (PP) were produced successfully for a biochip designed for protein crystallisation and analysis.

Microfluidic biochip injection moulded using a patterned SU-8/Si mould insert