Can you manufacture my microfluidic design?

Yes. We manufacture a wide range of custom microfluidic components and chips, from simple channel layouts to highly complex microfluidic devices. Our engineering team reviews every design to evaluate manufacturability and recommends optimizations when needed.

Which materials are best for microfluidic devices?

The best material depends on your application. We commonly process COC, COP, PMMA, PC, PEI (Ultem), PEEK and other engineering polymers selected for optical performance, chemical resistance, dimensional stability and biocompatibility.

Can you review my design before tooling?

Absolutely. We provide Design for Manufacturability (DFM) support to identify potential manufacturing challenges before tooling begins. This helps reduce development time, improve product quality and minimize costly design revisions.

Do you manufacture both prototypes and production volumes?

Yes. We support projects from early-stage prototypes to low-, medium- and high-volume production. Our manufacturing approach is designed to help customers scale efficiently as their products move toward commercialization.

How do I start a custom microfluidic project?

Simply send us your CAD files, drawings or project requirements. Our engineering team will review your design, discuss your manufacturing goals and prepare a tailored quotation with recommendations for tooling, materials and production.

How long does a typical microfluidic manufacturing project take?

Project timelines depend on design complexity, tooling requirements and production volume. After reviewing your project, we'll provide an estimated schedule for design review, tooling and production.

Microfluidic Design & DFM for Injection Molding

Turn your microfluidic concept into a manufacturable thermoplastic device. Micromolds helps engineering teams adapt existing chip designs for micro injection molding, bridging the gap between functional prototypes and repeatable production.

From Microfluidic Prototyping to Scalable Manufacturing

Successful microfluidic manufacturing starts with a design developed around the constraints of the intended production process. Micromolds engineers review channel geometry, wall thickness, draft angles, material requirements and critical dimensions before tooling begins.

Early DFM helps identify filling, demolding, warpage, bonding and tolerance risks before they become costly tooling changes.

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What we help optimize

✓ Microchannel geometry

✓ Wall and feature thickness

✓ Draft angles and demolding

✓ Material requirements

✓ Critical dimensions and tolerances

✓ Production scalability

Microfluidic Design Guidelines for Manufacturing

Microfluidic channel geometry must balance fluidic performance with the practical limits of tooling, polymer flow and demolding.

Channel Dimensions

Maintain a minimum channel size of 50 μm, with 100–200 μm recommended for robust manufacturing and repeatable production.

Aspect Ratio

Design channels with an aspect ratio between 1:1 and 5:1 to improve mold filling and feature replication.

Draft Angles

Apply 1–3° draft angles on vertical walls to simplify demolding while protecting delicate microstructures.

Uniform Wall Thickness

Keep wall thickness consistent and limit channel depth to approximately 70% of the total part thickness to reduce sink marks and warpage.

Corner Radii

Replace sharp internal corners with fillets to improve polymer flow and minimize trapped air.

Not sure where to start?

Reach out — our team will guide you in the right direction.

Book an Assesment

Designing Microfluidic Chips for Injection Molding

Microfluidic designs intended for injection molding must account for tooling access, polymer flow, gate location, venting, demolding and material behavior. These requirements should be considered before the production mold is manufactured.

Tooling Considerations

✓ Precision micro tooling

✓ Gate location and polymer flow

✓ Micro-venting

✓ Mirror-polished optical surfaces

✓ Prototype and production tooling

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Material Selection During Microfluidic Design

Material selection should begin during the design stage because polymer properties affect channel replication, optical performance, chemical compatibility, dimensional stability and downstream bonding.

Micromolds works with thermoplastics including COC, COP, PMMA, PC and PEI for microfluidic applications.

Explore Microfluidic Materials

Designing Microfluidic Devices for Bonding and Assembly

Bonding requirements should be defined before the microfluidic design is finalized. Cover-layer geometry, bonding area, material compatibility, surface condition and channel dimensions can all affect sealing performance.

Considering assembly during DFM helps reduce the risk of channel deformation, incomplete sealing and downstream process changes.

Explore Microfluidic Bonding & Assembly

Have a Project That Requires Precision Manufacturing?

Share your project requirements and any available drawings or specifications. Our engineers can discuss suitable tooling and micro injection molding solutions.

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