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A novel hot embossing/low temperature ethanol solvent bonding method for the fabrication of polymethylmethacrylate (PMMA) field flow fractionation devices has been developed. The separation channel on a PMMA substrate was generated by a hot embossing process without vacuum. Special temperature-pressure profiles were used to analyze the influence of the hot embossing parameters. After the hot embossing process, ethanol solvent bonding was used to seal the separation channel on the PMMA substrate. The experimental results show that the bonding strength with ethanol solvent bonding at  35 °C (aspect ratio (depth/width): 0.043) is 3.05 MPa, and the deformation percentage is very low (0.54%). A burst pressure test indicated that the as-prepared PMMA gravitational field flow fractionation device has a very high burst pressure. Furthermore, the higher resolution of the as-prepared PMMA gravitational field flow fractionation device in the separation of wheat and starch particles shows that the hot embossing/low temperature ethanol solvent bonding technique will have potential commercial value

Gravitational Field-Flow Fractionation Devices Fabricated via a Hot Embossing/Thermal Bonding Method