Prototyping and small series fabrication of micro structured polymer components required for design testing and validation in the development of e.g. micro fluidic µTAS applications are performed at IMM by methods of micro molding as well as by means of direct structuring of blanks from various plastic materials. The methods include:

• Vacuum casting of e.g. silicone, polyurethane and epoxy resins  
• Hot embossing of thermoplastic materials
• Excimer laser ablation i.e. of PMMA, COC and others
• Precision and ultra precision CNC milling

In particular the latter allows a quick response to design changes and hence, helps to reduce the overall development time required to realize a specific application.

Larger numbers of micro structured polymer components such as micro fluidic chips for analytical or diagnostic applications are realized by micro injection molding, which IMM performs in cooperation with selected, well-versed partners from the plastics manufacturing industry.

For the manufacturing of micro structured metal molds or mold inserts IMM has different processes at its disposal. Depending on product requirements such as structure dimensions, tolerances and surface quality molds can be realized by

• Mechanical processing including precision and ultra precision milling as well as wire and die sinking electrical discharge machining  
• Mastering methods based on Excimer laser ablation or UV-lithography in combination with Advanced Silicon Etching (ASE). Both methods employ replication of the master by means of electroforming to obtain metal moulds e.g. from nickel or nickel hard alloys.