Hot roller embossing for the creation of microfluidic devices

We report on the hot roller embossing of polymer sheets for the creation of microfluidic structures. Measurements conducted on 100 mum features showed that the lateral dimensions could be replicated to within 2% tolerance, while over 85% of mould depth was embossed. Feature sizes down to 50 mum and feature depths up to 30 mum had been achieved. At lower temperatures, asymmetric pile up of polymer material outside embossed regions was observed with higher pile up occurring on the trailing side of the embossed regions.