Polystyrene (PS) Molding Microfluidics Setup

From PDMS to highly versatile and transparent Polystyrene PS

Fast process

Fabricate Polycarbonate chips in only 1 hour

No need for a clean room

The whole microfabrication process is performed outside of a clean room

High versatility

Easily molded into various shapes and sizes

Polystyrene modling microfluidics setup

PDMS chip microfabrication

PDMS is the most commonly used material for the fabrication of microfluidic devices.

 

In our molding setup, the microfabrication of PDMS chips is performed outside of a clean room and begins by blending PDMS with a curing agent and degassing inside a desiccator. Then, the elastomer is carefully poured onto the mold and undergoes curing in a conventional oven. After completion, the chips undergo demolding and precise cutting, while inlet perforations are made using biopsy punchers. Finally, the PDMS is securely attached to a glass slide following treatment in a plasma cleaner.

PDMS setup schematics for comparison with thermoplastic molding setup

However, PDMS limited chemical compatibility, high gas permeability, and low throughput are reasons why researchers started looking for replacement materials, such as thermoplastics.

Switching to Polycarbonate (PS) molding

Consequently, our engineers and researchers turned the PDMS microfabrication process into a thermoplastic molding setup for microfluidic chip fabrication. Particularly, they developed the Polystyrene (PS) molding setup.

Polystyrene (PS) is a particularly interesting thermoplastic for chip microfabrication due to its many advantages. It’s an inert, rigid, biocompatible, and commercially available material adapted for mass manufacturing. Its low production costs present a cost-effective option for various applications. Moreover, transparent grades of PS are available, making it suitable for applications where visibility is important. Furthermore, PS material can be easily molded into various shapes and sizes, offering versatility in design and applications.

Polystyrene microfabrication follows the same steps as thermoplastic chip microfabrication, and both can be performed outside of a clean room.
polystyrene ps material chip fabrication
In our polystyrene molding microfluidic setup, we streamline the initial time-consuming phase by implementing a significantly faster hot-embossing process. Subsequently, chip preparation is simplified using drilling tools. Using the existing plasma cleaner and adding a laminator, the chip is sealed.

By integrating our recommended heat press and laminator into your workflow and adhering to our guidelines, you can seamlessly transition from PDMS microfabrication to PS material molding setup.

Your PDMS microfabrication process is different, and you don’t have all the listed equipment? Don’t worry; we’ve got you covered! We can provide you with all the necessary pieces and consumables; just drop us a line!

We recently published a review about the diverse materials and innovative fabrication and molding techniques used in microfluidic chip design.

Compatibility and Applications

The PS molding setup can also be used with:

PMMA-device-station

PMMA Device Station

From mold development to high-resolution PMMA chip fabrication

✓ Fast process

✓ Multiple applications

✓ Simple and innovative setup

PMMA

thermoplastic molding finishing the chip

Polycarbonate (PC) Molding Microfluidics Setup

From PDMS to highly versatile and performant Polycarbonate PC

✓ Fast process

✓ No need for a clean room

✓ High impact strength

Polycarbonate

thermoplastic molding using the heat press

COC Polymer Molding Microfluidics Setup

From PDMS to low-impurity high-performance COC polymer

✓ Fast process

✓ No need for a clean room

✓ Adaptable to your needs

COC/COP

And many more! 

Microfluidic chips produced with PS molding can be employed in: 

Nanoparticle for drug delivery adapted

Microfluidics Nanomaterial Synthesis Pack

Microfluidics for production of nanomaterials using sheath flow focusing

✓ Efficient synthesis. ofnanomaterials

✓ Easy microfluidic system implementation

✓ Biomedical applications

Lab-on-a-chip applications (e.g. nanomaterial synthesis)

Gut-on-a-chip

Gut-on-a-chip pack

Intestinal cells coculture under flow, mimicking the gut physiology

✓ All microfluidic pieces included, quick and easy assembly

✓ Dynamic culture conditions

✓ Advanced in viro/ex vivo

Gut-on-chip

Applications requiring specific-chip design and chemical inertia

And many more! 

Polystyrene ps material microfluidic chip

Technical specifications

The polystyrene (PS) molding microfluidic setup comprises:

Heat press with double heating plate

Components Specifications
Dimensions 420*550*680mm
Max temperature 300 °C
Pressure range 0-25 tons

Laminator

ComponentsSpecifications
Dimensions270*545*130 mm (L x w x h)
Max laminated width335 mm
Max laminated thickness35 mm
Max temperature140 °C

Options: Drilling machine 

Consumables:Polystyrene sheets

Frequently asked questions

Does the process also involve mold fabrication?

Currently, the polystyrene (PS) molding microfluidic setup focuses on the chip fabrication and bonding from a pre-existing mold. However, we do have expertise to advise you in how to make your own molds.

Resolutions as low as 15 µm (channel width) for an aspect ratio of 2:1 can be achieved.

Based on internal testing, up to 3.5 bar.

The chip can be closed with a thermoplastic slide, a microscope glass slide or a microscopy-compatible polymer slide.

Polystyrene is optically transparent and well-adapted to microscopy.

eu_funded_en
Marie Curie Doctoral Networks 2024 Microfluidics Innovation Center
biopros european project logo microfluidics innovation center
micro4nano European project logo - microfluidics innovation center

Funding and Support

The BIOPROS and MICRO4NANO projects results helped develop this instrument pack, with funding from the European Union’s Horizon research and innovation program under HORIZON-CL4-2021-DIGITAL-EMERGING-01-27, grant agreement no. 101070120 and the European Union under H2020-MSCA-RISE-2020, grant agreement No. 101007804.

Products & Associated Accessories

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