Application of ultrasonic welding to the rapid prototyping of microfluidic systems for biotechnology

Abstract

This paper introduces an alternative technique for the development of microfluidic systems for biotechnology based on mechanical machining and ultrasonic welding. Advantages of this approach over existing prototyping approaches involving the rapid development of tooling include: (a) short cycle time, (b) design flexibility, and (c) low cost manufacturing. In addition, the process provides a migration path to high volume production. A limitation of this system is that it cannot practically produce microchannels smaller than about 250 μm (0.010 in). However, for many biological cell-based biosensors, this feature scale seems well suited based on cell viability results. Several issues are discussed relevant to this approach, including bond strength, seal leakage, and sterilization.