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Here we present a new methodology for chemical polishing of microchannels in polycarbonate (PC). Tuning the time of exposition and the concentration of ammonia, the roughness arising from the micromachining process can be significantly reduced or completely removed while preserving the structure of microchannels. Besides smoothing out the surface, our method modifies the wettability of the surface, rendering it hydrophobic. The method increases the optical transparency of microchannels and eliminates undesired effects in two-phase microfluidic systems, including wetting by aqueous solutions and cross-contamination between aqueous droplets that could otherwise shed satellites via pinning.

A Method for Simultaneous Polishing and Hydrophobization of Polycarbonate for Microfluidic Applications