Comparison between Injection Molding (IM) and Injection-Compression Molding (ICM) for Mass Manufacturing of Thermoplastic Microfluidic Devices

Point-of-care (PoC) and organ-on-chip (OoC) devices represent promising microfluidic applications for in vitro analysis and miniaturized analytical studies, reducing the need for traditional animal-based tests for drug discovery and toxicity studies. Using thermoplastics in microfluidic device manufacturing provides interesting functionalities for expansion of these devices into market. However, market growth requires manufacturing large quantities for low cost, which can be achieved using injection molding techniques. This work involves the design of a microfluidic device with different aspect ratio channels to compare injection molding (IM) and injection-compression molding (ICM) processes, as well as the design and manufacturing of a metallic insert containing machined inverted microstructures. Injected parts are validated visually, dimensionally, and functionally. The differences between both techniques and two grades of cyclic olefin copolymer materials are analyzed to evaluate microfluidic device mass production feasibility concluding that although the machining process for inverted high aspect ratio microstructures is not mature yet, both IM and ICM processes allow the mass manufacturing of microfluidic devices in thermoplastic. Parts processed by ICM show better replicability of microfluidic structures and less internal stresses generate during the injection process than IM parts, highlighting the potential of this process to achieve thermoplastic microfluidic devices to market. A comparison between injection molding and injection-compression molding techniques for the mass manufacturing of thermoplastic microfluidic devices is performed. This work presents the characterization of two interesting thermoplastics for microfluidic applications, the manufacturing and characterization of a metallic insert containing microfluidic structures and the injection and characterization of thermoplastic microfluidic devices.image

Automated summary

Point-of-care and organ-on-chip devices are promising microfluidic applications for in vitro analysis and miniaturized studies, reducing reliance on animal testing. This study compares injection molding and injection-compression molding techniques for mass manufacturing of thermoplastic microfluidic devices, highlighting the potential of both techniques for producing these devices at a large scale and low cost.