Rapid Microfluidic Device Fabrication Capabilities

Custom Microfluidic Devices from $90/part

Get custom microfluidic device fabrication quickly and cost-effectively with Potomac’s FAST TRACK manufacturing process. Our digital fabrication technologies are specifically geared to rapidly turning custom designs into functioning devices at a fraction of the time and cost it takes with traditional manufacturing processes.

Starting with prototyping, you can get a minimum of 10 parts for just $90 per part. And most importantly, if you need to modify your design, manufacturing is just a CAD file change away. Once you are ready to move to higher volume, unit price is typically less than $15 per part.

FAST TRACK includes generating and precisely replicating channel designs in your substrate, laser micromachining vias and holes, as well as bonding cover slips. Clearly, to keep prices this low, Potomac’s microfluidic device fabrication process has specific design parameters that are listed below.

For any microfluidic designs that don’t fit into the FAST TRACK design parameters, we are happy to work closely with you to develop a manufacturing process suited to your application. Please contact us today to discuss how we can help you manufacture custom parts for your next Microfluidic project.

FAST TRACK MICROFLUIDIC DEVICE MATERIALS:

SUBSTRATES 
MATERIALSPMMA, POLYSTYRENE
THICKNESS1.5 MM +/- 0.2MM
MAXIMUM DIMENSION (LENGTH OR WIDTH)50 MM
MINIMUM DIMENSION15 MM
MINIMUM DISTANCE FROM EDGE2 MM

FAST TRACK COVER AND BONDING OPTIONS:

MICROFLUIDIC DEVICE COVER 
MATERIALPOLYESTER
BONDINGPRESSURE SENSITIVE ADHESIVE
BONDING MATERIALACRYLIC (HYDROPHOBIC OR HYDROPHILIC OPTIONS)
THICKNESS75 MICRONS TO 150 MICRONS

 FAST TRACK CHANNEL DIMENSIONS

CHANNELS 
MINIMUM WIDTH50 MICRONS
MINIMUM DEPTH50 MICRONS
MAXIMUM WIDTH400 MICRONS
MAXIMUM DEPTH200 MICRONS
MAXIMUM ASPECT RATIO (DEPTH / WIDTH)2.0
WALL TAPER (DRAFT)30 DEGREES
MULTIPLE CHANNEL DEPTHSNOT ALLOWED

FAST TRACK VIAS AND HOLES

VIAS AND HOLES 
MINIMUM DIAMETER200 MICRONS

FAST TRACK DRAWING REQUIREMENTS

DESIGN AND DRAWING REQUIREMENTS  
FORMAT.DXF
OBJECT TYPESPOLYLINES AND CIRCLES ONLY
CLOSED STRUCTURE TYPESPOLYLINES OR CIRCLE ONLY
POLYLINE SEGMENT OVERLAPSNOT ALLOWED
ARC OR CIRCLE SEGMENT OVERLAPSNOT ALLOWED

Additional drawing and fabrication guidelines

  1. Draw closed structure dimensions 20 microns larger than desired fabricated dimension to compensate for fabrication tool size.
  2. All shapes should be closed and of the polyline (connected lines and/or arcs) or circle types.
  3. Be sure to account for wall draft. Your drawing will determine sizes at the bottom of the channel or well. Fabricated feature dimensions will be larger than drawn at the top of the channel or well.
  4. Hydrophilic cover adhesive will be used unless otherwise specified.

Full-feature product and process development

If you microfluidic device fabrication design does not meet the design rules for the FAST TRACK program, please contact us to discuss your application. We can work with you to develop suitable prototyping and production processes for other microfluidic device features, such as:

  • Alternative materials: COC, COP, FEP, Polyimide
  • Larger or smaller device sizes
  • Larger or smaller feature sizes
  • Alternative bonding methods: Thermal, solvent assisted
  • Multilayer stacks
  • Component integration