Low cost method for hot embossing of microstructures on PMMA by SU-8 masters

Polymer based microfabrication technologies are used extremely in Bio-MEMS, especially in Microfluidic devices in recent years. In this paper, a novel method for fabrication of microstructures on a polymeric material using hot embossing lithography process is presented. The proposed method involves usage of low cost materials and procedure with respect to previous methods and can be processed in a short time. The master is made from SU-8 on an inexpensive glass substrate which is patterned by standard lithography. The embossing pressure can be increased in our master as the glass substrate used in this paper is more robust than Silicon. Master robustness and SU-8 to glass adhesion is optimized by some substrate pretreatments and SU-8 baking time and temperatures. Microchannels are replicated on a Polymethylmetacrylate (PMMA) stamp which is a plexiglass sheet with thickness of 1 mm. Significant embossing parameters including temperature, pressure and time are discussed and optimum values are determined. Microchannels are imprinted by depth of 50 μm and minimum width of 15 μm and aspect ratio more than 3. The microchannels are sealed by a PMMA cap using thermal annealing bonding.