Laser & Engineering technologies cluster LITEK was established in 2010 but cooperation between science and SMEs continues for more than 20 years already. It all started when manufacturers of laser systems in cooperation with scientific institutions began to develop unique products in the field of photonics. Companies of LITEK together with scientific institutions understood that combining different areas of knowledge, close cooperation, interdisciplinary (in photonics and engineering fields) sharing ideas and convenient business environment are one of the main reasons for more efficient business operations and growing results. That’s how companies and scientific institutions got together in a cluster – LITEK. Being a part of the cluster allows its members not to compete with each other but by combining resources and knowledge direct all the energy for the competition in international markets and easier enter new ones. We had an opportunity to spread the word about plastic micro injection molding for the Laser & Engineering technologies cluster (LITEK) member companies. Our CEO Dominykas Turčinskas presented our capabilities and explained the main differences of micro injection molding and traditional molding.

The iGEM (International Genetically Engineered Machine Competition) is the largest annual international competition in synthetic biology. Teams from best world universities competes here with their researches and scientifically based projects which solve actual world problems. We are proud to be part of Vilnius-Lithuania iGEM 2020 team helping them out with our mechanical engineering skills and knowledge. The Vilnius-Lithuania iGEM 2020 team project focuses on a critical issue in the food industry and aquaculture - infectious diseases in fish, which in turn wipes off more than $ 6 billion annually in fish farming industry (World Bank, 2014). While Earth resources are scare, the growing human population is leading to a growing demand for them, thus ability to effectively and sustainably produce high levels of food is becoming more an more relevant issue. The presumption of this project is that identified appropriate mechanisms for disease prevention, detection and treatment will greatly reduce production losses caused by these infectious pathogens and will eliminate the use of antibiotics in fish farms. Vilnius-Lithuania iGEM 2020 project consists of three main parts: Early detection of exogenous bacterial diseases by the use of strip test; Treatment based on the action of exolysins; Prevention based on the development of proteins immobilized in alginate beads for vaccination. As it can be easily guessed "Micromolds" team will mainly contribute in the first part of this huge project. We are really proud to be part of Vilnius-Lithuania iGEM 2020 team helping to design and manufacture strip testing device to indicate infectious bacteria in fish farms. However, it is not our first time we participate in collaborations with Vilnius University. Our task is to design 3D model of strip test which could be later on manufactured with 3D printing technology FDM. This will be only a prototype to demonstrate the testing procedure on fish farm site. The main design constrains we have discussed for this strip test device are: Material must be suitable for FDM 3D printing; Sample well should have converging form for sample liquid to freely drain inside; The housing should have transparent section for test and control lines indication; Fixation at points of membranes should be minimal not to interfere diffusion; Strip test device should be reusable with one-time use strips; Dimensions: height: 4 mm; length: 70 mm; width: 10 mm. Example of 3D Printed Strip Test Structure This project is still in process and will be updated. ...

Microfluidics fabrication involves creating microscopic channels, chambers, and fluid-handling structures used in diagnostic devices, lab-on-a-chip systems, and analytical applications. Methods such as soft lithography, micromilling, laser machining, 3D printing, hot embossing, and injection molding offer different advantages depending on the material, channel geometry, development stage, and required production volume. For engineers developing microfluidic devices, the challenge is not simply selecting a method capable of producing the required features. A prototype may demonstrate excellent fluidic performance but behave differently when manufactured using another material or production process. Understanding these differences early can help avoid redesigns and establish a more reliable transition from laboratory development to commercial manufacturing. What Is Microfluidics Fabrication? Microfluidics fabrication is the process of manufacturing structures that control the movement of small fluid volumes through precisely defined channels and chambers. These features can range from hundreds of micrometers to only a few micrometers, depending on the application and fabrication technology. At this scale, channel dimensions, surface properties, and material characteristics can significantly influence fluid behavior. Small variations in channel height or width may change hydraulic resistance, while differences in surface chemistry can affect wetting, adsorption, and interactions with biological samples. The appropriate fabrication method therefore depends on more than dimensional accuracy. Engineers must also consider optical requirements, chemical compatibility, bonding, and whether the device will be manufactured as a small number of prototypes or in repeated production batches. Common Microfluidics Fabrication Methods Several technologies are used to manufacture microfluidic chips, but they are not equally suitable for every development stage or application. PDMS soft lithography is widely used in research and early prototyping. It allows engineers to replicate microscopic channel structures relatively quickly and evaluate fluidic designs before committing to more complex manufacturing processes. However, PDMS has material characteristics, including gas permeability, flexibility, and sensitivity to certain solvents, that may limit its suitability for some commercial applications. CNC micromilling and laser machining enable the direct fabrication of microchannels in rigid materials without requiring a complete production mold. These methods can be valuable when designs require frequent modifications or when engineers want to test features in thermoplastics such as PMMA. Nevertheless, machining marks, feature accessibility, surface quality, and processing time can become limitations as component complexity or production quantities increase. 3D printing provides another approach to rapid design iteration, especially for complex geometries and early functional evaluation. Its suitability for microfluidics depends on the printing technology, achievable resolution, material properties, and surface finish. Features produced successfully through additive manufacturing may still require modification when transferred to another fabrication process. Hot embossing and injection molding are established methods for replicating microstructures in thermoplastic materials. Hot embossing uses heat and pressure to transfer features from a mold into a polymer substrate, while injection molding fills a precision mold cavity with molten polymer. Both can support repeated production, although their suitability depends on channel geometry, material selection, production volumes, and process requirements. For devices requiring repeatable polymer components at increasing volumes, microfluidic injection molding can provide an efficient manufacturing route once the design and tooling have been appropriately developed. Why Successful Prototypes Can Fail During Scale-Up One of the most important challenges in microfluidics fabrication appears when a working prototype is transferred to a different material or manufacturing technology. A device that functions correctly in PDMS, for example, may require adjustments before it can be produced through thermoplastic injection molding. The reason is that fabrication methods influence more than the shape of the channels. Material stiffness, surface chemistry, shrinkage, thermal behavior, and bonding requirements can all affect the finished device. A channel successfully replicated through soft lithography may be difficult to reproduce in a rigid thermoplastic if its geometry creates filling or demolding challenges. Similarly, a design that performs well during open-channel testing may behave differently after bonding introduces additional thermal or mechanical stresses. These differences become particularly important for devices involving precise flow distribution, optical detection, or sensitive biological assays. The transition to production must preserve the features responsible for device functionality, not simply reproduce the external appearance of the original prototype. This is why manufacturing feasibility should be considered while the design is still being developed rather than after the geometry has been finalized. Choosing a Fabrication Method With Production in Mind Selecting a microfluidics fabrication method should begin with the device's functional requirements and intended production strategy. Early prototypes may prioritize flexibility and fast iteration, while production-ready devices require consistent geometry, stable materials, reliable sealing, and repeatable manufacturing processes. For teams planning to move toward injection molding, design for manufacturability can help identify challenges related to channel aspect ratios, wall thickness, draft angles, polymer flow, and bonding. Addressing these requirements early may prevent modifications to features that have already undergone extensive functional validation. The tooling strategy also matters. Precision microfluidic mold tooling must support accurate microfeature replication while accounting for filling, venting, cooling, and demolding. Where the design remains under development, prototype tooling may provide an opportunity to evaluate critical features in the intended production material before investing in more extensive tooling. The objective is not necessarily to use injection molding from the earliest development stage. It is to ensure that decisions made during prototyping do not create avoidable barriers to the intended manufacturing process. From Microfluidics Fabrication to Reliable Production Successful microfluidic device development requires a connection between fabrication, functional validation, and manufacturing engineering. A prototype demonstrates whether the concept can work, while production development establishes whether the same functional requirements can be achieved consistently using the selected materials and processes. At Micromolds, we support this transition through microfluidic design for manufacturability, precision tooling, micro injection molding, bonding, and assembly. By considering these stages together, our engineering team helps identify potential manufacturing constraints before they lead to extensive tooling modifications or production delays. If your microfluidic device has passed initial testing and you are evaluating its suitability for injection molding, an early feasibility review can help clarify the next steps. Request a microfluidic manufacturing feasibility review.

Micromolds will participate in the 25th Berlin Security Conference (BSC 2026), taking place on November 3–4, 2026, at Vienna House by Wyndham Andel’s Berlin, Germany. Exhibiting as part of the Lithuanian National Pavilion, Micromolds will showcase its expertise in micro and precision injection molding, high-precision tooling, and manufacturing complex polymer components. Visitors are invited to meet us at Stand 26 to explore our manufacturing capabilities, examine selected component samples, and discuss potential engineering and manufacturing collaborations. Lithuania as Partner Nation at BSC 2026 The Berlin Security Conference is one of Europe's major security and defence policy forums, bringing together representatives from governments, armed forces, NATO, European institutions, research organisations, and industry. In 2026, the conference celebrates its 25th edition, with Lithuania serving as the official Partner Nation. Micromolds will join 12 other Lithuanian organisations at the national pavilion, representing a range of technological and industrial capabilities. The announced programme includes Lithuanian President Gitanas Nausėda, European Commissioner for Defence and Space Andrius Kubilius, German Defence Minister Boris Pistorius, and senior NATO representatives. Beyond broader security and geopolitical discussions, the agenda addresses defence innovation, European capability development, research and development, and industrial cooperation. These discussions also highlight an important engineering challenge: translating advanced technologies into reliable products that can be manufactured consistently and at scale. Precision Manufacturing for Advanced Technologies As products become smaller and more complex, manufacturers face increasing demands for dimensional accuracy, material performance, and production repeatability. Micromolds brings experience from medical devices, microfluidics, and high-tech electronics, supporting engineering teams developing technically demanding polymer components. Our capabilities include: Design for Manufacturing (DFM): Evaluating part geometry, materials, tolerances, and manufacturability before tooling begins. Precision Tooling: Designing and manufacturing high-precision injection molds in-house. Micro and Precision Injection Molding: Producing complex polymer components with micro-scale features and tight dimensional requirements. Overmolding and Assembly: Supporting multi-component manufacturing and integration requirements. Quality Control: Dimensional inspection, process control, and an ISO 13485-certified quality management system. By integrating engineering, tooling, and manufacturing expertise, Micromolds helps customers address technical challenges early and establish repeatable production processes. We look forward to exploring how these capabilities may support companies developing emerging technologies and advanced engineering systems. Learn more about our micro injection molding and precision tooling services. Meet Micromolds at Berlin Security Conference 2026 Our participation in BSC 2026 is an opportunity to connect with technology developers, engineering teams, and potential manufacturing partners across different industries. At our stand, visitors will be able to explore selected manufacturing samples and discuss technical requirements, materials, tooling, prototyping, and serial production. Event: Berlin Security Conference 2026 Date: November 3–4, 2026 Venue: Vienna House by Wyndham Andel’s Berlin, Germany Location: Lithuanian National Pavilion | Stand 26 Attending BSC 2026? Visit Micromolds at Stand 26 to discuss your next engineering or manufacturing project. Contact Micromolds to arrange a meeting. For further event information, visit the official Berlin Security Conference website.

Microfluidic device scale up is a critical stage between successful prototyping and commercial production. A device that performs well in laboratory testing may still require significant design, material and process optimization before it can be manufactured consistently at scale. Many devices that perform well during research and prototyping encounter challenges when transitioning to large-scale manufacturing. Scaling a microfluidic device for commercial manufacturing requires careful planning, design optimization, material validation, and manufacturing expertise. Decisions made during early development directly influence production efficiency, product quality, regulatory compliance, and overall manufacturing costs. Rather than treating manufacturing as the final project stage, successful development teams integrate manufacturing considerations from the beginning. This approach minimizes engineering changes, reduces development risks, and creates a smoother path from prototype to commercial production. Why Microfluidic Device Scale Up Is More Than Increasing Production Volume Scaling a product is often misunderstood as simply producing more parts. In reality, commercial manufacturing introduces new engineering and quality requirements that may not be visible during prototype development. At larger production volumes, manufacturers must ensure: Consistent dimensional accuracy Stable manufacturing processes Repeatable material performance Reliable assembly Efficient quality control Cost-effective production A prototype manufactured successfully in small quantities may require significant design modifications before it becomes suitable for commercial production. Start with Design for Manufacturing (DfM) One of the most important steps in scaling a microfluidic device is applying Design for Manufacturing (DfM) principles. DfM evaluates whether a product can be manufactured efficiently without compromising functionality. For microfluidic devices, engineers typically review: Microchannel geometry Wall thickness Draft angles Polymer flow Gate location Venting strategy Cooling performance Shrinkage compensation Part ejection Small design improvements identified during DfM reviews can reduce tooling complexity, improve manufacturing consistency, and lower production costs. Because tooling modifications become significantly more expensive after mold completion, DfM should be completed before production tooling is commissioned. Select Production-Ready Materials Early Material selection affects both device performance and manufacturing efficiency. Although prototype materials may provide acceptable laboratory performance, commercial manufacturing often requires production-grade thermoplastics capable of delivering consistent quality across thousands or millions of parts. Material behavior must also be evaluated under actual microfluidic injection molding conditions, as flow, cooling and shrinkage can influence the replication of critical microfeatures. Common materials include: Material Typical Applications COC Optical diagnostics, Lab-on-a-Chip COP High optical performance and chemical resistance PMMA Disposable analytical devices PC Structural components requiring high strength PS High-volume diagnostic consumables Material selection should consider: Optical clarity Chemical resistance Sterilization compatibility Biocompatibility Bonding method Manufacturing consistency Choosing production materials early helps avoid expensive redesigns during commercialization. Validate Manufacturing with Prototype Tooling Moving directly from functional prototypes to production tooling introduces unnecessary risk. Prototype tooling provides an intermediate step that allows engineers to manufacture production-intent components before investing in hardened production molds. Prototype tooling helps validate: Manufacturability Dimensional accuracy Material behavior Assembly processes Bonding compatibility Process repeatability This stage frequently identifies opportunities for design optimization while tooling modifications remain relatively inexpensive. Plan Production Tooling Strategically Production tooling represents one of the largest investments in commercial manufacturing. Unlike prototype tooling, production molds are designed for: High production volumes Long tool life Stable process performance Short cycle times Automated manufacturing During tooling development, engineers evaluate: Number of cavities Cycle time optimization Cooling efficiency Mold durability Maintenance requirements Quality inspection strategy Careful tooling planning improves long-term manufacturing efficiency and lowers the cost per part. Design for Automated Manufacturing As production volumes increase, manual assembly becomes increasingly inefficient. Commercial manufacturing should therefore consider automation opportunities during the design stage. Examples include: Automated part handling Robotic assembly Automated inspection Vision systems Laser marking Inline leak testing Designing products for automation reduces production costs while improving repeatability and product quality. Consider the Complete Assembly Process Many microfluidic devices contain more than molded plastic components. Typical assemblies may include: Membranes Filters Optical windows Reagents Sensors Connectors Adhesive layers Assembly should be evaluated alongside component manufacturing rather than after tooling has been completed. A design that simplifies assembly often reduces overall manufacturing costs more effectively than optimizing the molded component alone. For devices that require sealed microchannels, the bonding process should also be considered during material and component design. Develop a Robust Quality Strategy Commercial manufacturing requires significantly more quality control than prototype production. Manufacturers typically establish inspection methods for: Critical dimensions Surface quality Optical characteristics Bond integrity Leak performance Functional testing Process validation and statistical process control help ensure consistent product quality throughout production. Common Challenges When Scaling Microfluidic Devices Transitioning from prototype development to commercial manufacturing often reveals engineering challenges that were not apparent during early development. Common issues include: Design Not Optimized for Manufacturing Laboratory prototypes often prioritize functionality over manufacturability. Material Changes Late in Development Changing polymers after tooling has been completed frequently requires expensive engineering modifications. Assembly Complexity Products containing multiple components may require unnecessary manual operations if assembly is not considered during product design. Inadequate Tooling Validation Skipping prototype tooling increases the likelihood of unexpected manufacturing problems during production. Poor Production Planning Manufacturing capacity, automation, inspection, and supply chain considerations should all be addressed before commercial launch. Commercial Manufacturing Readiness Checklist Before releasing a product for production, engineering teams should confirm: Product design finalized DfM review completed Production material selected Prototype tooling validated Production tooling strategy defined Assembly process verified Bonding method validated Quality inspection established Manufacturing documentation completed Production capacity planned Completing these activities significantly improves manufacturing readiness while reducing commercialization risks. Conclusion Successful microfluidic device scale up requires more than increasing production volume. It demands a structured transition from prototype development to a stable and repeatable production process. It demands a structured approach that integrates design optimization, material selection, tooling strategy, assembly planning, and manufacturing validation. By addressing these factors early, engineering teams can reduce development risk, improve manufacturing efficiency, and accelerate the transition from prototype to commercial production. Commercial manufacturing is not simply the final stage of product development—it should be considered throughout the entire development process. Ready to Scale Your Microfluidic Device? Moving from a functional prototype to repeatable production requires the right decisions across design, materials, tooling and process development. If you are preparing a microfluidic device for scale up, contact Micromolds to discuss your design, production requirements and next manufacturing steps.

Choosing a microfluidic injection molding manufacturer requires more than comparing tooling costs, lead times, or a single advertised tolerance. The right manufacturer must be able to reproduce critical microfeatures consistently, verify them with suitable metrology, and maintain that capability as production volumes increase. For engineers and procurement teams comparing microfluidic injection molding manufacturers, the key question is simple: can the supplier manufacture, measure, and repeatedly reproduce the features that determine how your device functions? This guide explains how to evaluate that capability before committing to tooling. 1. Start With the Features That Determine Device Performance Not every dimension on a microfluidic component carries the same manufacturing risk. Before evaluating manufacturers, identify the features that directly affect device function. Depending on the design, these may include: microchannel width and depth; channel intersections; sealing surfaces; inlet and outlet features; thin walls; optical surfaces; alignment features; flatness; microtextures or other functional microfeatures. This gives the manufacturer a much better basis for evaluating the component. A capable supplier should be able to distinguish between function-critical dimensions and conventional part dimensions and discuss how each critical feature will be produced and verified. Do not select a manufacturer based on one tolerance number A statement such as “we can mold ±X μm” does not tell you whether your particular component can be manufactured reliably. Achievable tolerances depend on the complete part and process, including: feature geometry; aspect ratios; wall thickness; material behavior; mold construction; gate position; filling conditions; shrinkage; venting; cooling; ejection; measurement method. The more useful question is: How will you manufacture, measure, and control this specific critical feature? A manufacturer should be able to answer that question before production tooling is finalized. 2. Evaluate Mold-Making Capability, Not Only Injection Molding For microfluidic components, tooling is a fundamental part of the manufacturing process. Microchannels, sealing areas and other small functional geometries originate in the mold. The accuracy and surface condition of the tooling therefore directly influence the molded component. When comparing manufacturers, investigate how the supplier handles: precision mold design; microfeature manufacturing; high-precision machining; EDM where required; grinding; polishing and surface finishing; mold inserts; dimensional inspection; tooling corrections and optimization. An important distinction is whether mold manufacturing and injection molding are treated as separate purchased services or as one engineering process. When tooling, molding and measurement are closely connected, deviations observed in molded parts can be traced back to mold geometry and process conditions more efficiently. This becomes increasingly important as feature dimensions decrease. 3. Check Experience With Microfluidic Polymers Material selection affects much more than the nominal dimensions of the finished component. Microfluidic devices may require optical performance, dimensional stability, controlled surfaces, chemical compatibility, bonding capability, or a combination of these properties. Materials used for injection-molded microfluidic components include COC, COP, PMMA and PS, depending on the application and device requirements. The manufacturer should understand how the selected polymer interacts with: part geometry → mold design → filling → cooling → shrinkage → final dimensions This is especially important for small channels and thin sections, where seemingly minor processing changes can affect feature replication. Material selection should therefore be discussed during DFM rather than after the mold has already been designed. 4. Ask How Critical Microfeatures Will Be Measured A microfeature is not meaningfully controlled unless it can also be measured. This is one of the most important questions to ask potential microfluidic injection molding manufacturers. The appropriate measurement strategy depends on the feature being evaluated. Channel depth, sealing-surface flatness and an external reference dimension, for example, may require different measurement approaches. The supplier should be able to establish a clear relationship between: drawing requirement → mold feature → molded feature → measurement method → acceptance criteria Ask specifically: Which critical dimensions will be measured? At what stage will they be measured? What measurement method will be used? How will measurement uncertainty relate to the specified tolerance? Will measurements be performed on the mold, molded parts, or both? How will dimensional changes between tooling iterations be documented? A sophisticated measurement system alone is not enough. What matters is whether the selected method can reliably verify the feature being specified. 5. Look Beyond the First Successful Sample A good first molded part proves that a geometry can be produced. It does not automatically prove that the same geometry can be reproduced consistently across production. This distinction is critical when evaluating a supplier. Microfluidic injection molding depends on controlled processing conditions such as: mold temperature; melt temperature; injection speed; injection and holding pressure; cooling conditions; cycle stability. The manufacturer should therefore be able to explain how critical molding parameters are established and controlled after initial sampling. For appropriate production programs, dimensional data and statistical process control can then be used to evaluate whether critical features remain within the required manufacturing window. The objective is not simply to produce parts that pass inspection. The objective is to establish a repeatable manufacturing process with sufficient margin around the specification limits. 6. Evaluate the Complete Development Path Supplier selection should consider what happens after the initial RFQ. A typical microfluidic injection molding project may progress through: CAD review → DFM → mold design → mold manufacturing → first samples → measurement → optimization → validation → serial production Ask potential manufacturers who is responsible for each stage. Important questions include: Who performs the DFM analysis? Who designs the mold? Where is the mold manufactured? Where are the first samples produced? Who measures the critical features? How are deviations investigated? How are mold corrections implemented? How is the optimized process transferred into production? The fewer uncontrolled handovers between these stages, the easier it is to identify and correct dimensional problems. For precision microfluidic components, this engineering continuity can be more important than selecting the lowest initial tooling quotation. 7. Determine Whether the Process Can Scale Prototype success does not automatically guarantee production readiness. Before choosing a manufacturer, consider the expected production volume and ask how the manufacturing strategy changes as volumes increase. The supplier should be able to explain: expected tooling strategy; cavity strategy where applicable; process monitoring; critical-dimension inspection; mold maintenance; handling of tooling wear; production traceability; management of engineering changes. This is particularly important when the same microfluidic geometry must be reproduced over a long production period. The objective should be to minimize the need for a major manufacturing redesign when moving from development into serial production. How to Compare Microfluidic Injection Molding Manufacturers Instead of comparing suppliers primarily by price, use a technical evaluation framework. Evaluation area What to verify Why it matters Microfeature capability Experience manufacturing comparable feature sizes and geometries Determines whether critical geometry is realistically manufacturable Mold manufacturing Precision tooling and ability to modify it Critical features originate in the mold DFM Engineering review before tooling Identifies manufacturing risks early Polymer processing Experience with relevant microfluidic polymers Material behavior affects replication and dimensional stability Metrology Measurement strategy for critical features Precision must be measurable to be controlled Process control Defined critical molding parameters Determines repeatability Scaling Development-to-production capability Reduces manufacturing-transfer risk Tool maintenance Defined maintenance and correction strategy Helps maintain dimensional consistency over time The strongest supplier is not necessarily the one claiming the smallest possible tolerance. It is the manufacturer that can provide a technically credible path from CAD geometry to verified, repeatable molded parts. What Should You Send When Requesting a Quote? A detailed RFQ allows a microfluidic injection molding manufacturer to identify risks before tooling begins. Whenever possible, provide: 3D CAD files; 2D drawings; clearly identified critical dimensions; required tolerances; selected polymer or material requirements; expected annual volume; initial production quantities; surface or optical requirements; assembly or bonding requirements; relevant functional requirements. Most importantly, identify which features determine whether the device works. Two geometrically similar parts can require very different manufacturing strategies when their critical requirements differ. Instead of requesting only a price, ask the manufacturer to review the design and identify the main manufacturing risks. This turns the RFQ into an engineering discussion rather than a simple price comparison. Discuss Your Microfluidic Injection Molding Project If you are evaluating a microfluidic injection molding manufacturer for a new or existing project, our engineering team can review your design, critical features, material requirements and expected production volumes. Contact Micromolds to discuss your project or send us your CAD files and technical requirements for an initial manufacturing review. Contact Us

Certification underscores company’s commitment to quality management and reliable manufacturing for medical and microfluidic applications. Precision micro injection molding company Micromolds has successfully renewed its ISO 13485 certification, reinforcing its quality management framework for ISO 13485 injection molding and medical device manufacturing. The certification further strengthens Micromolds’ position as a trusted partner for engineering teams developing high-precision components for regulated applications, including medical devices and microfluidic systems. “Renewing our ISO 13485 certification reflects our commitment to controlled, repeatable, and traceable manufacturing processes. It ensures that our customers can rely on consistent quality when developing products for regulated environments.” – Dominykas, CEO at Micromolds. Commitment to Quality and Process Control ISO 13485 is a globally recognized standard for quality management systems specific to the medical device industry. It ensures that organizations maintain strict control over production processes, documentation, and risk management. With this recertification, Micromolds continues to practice: Structured and validated manufacturing workflows Full traceability across production stages Controlled process environments Consistent quality assurance protocols. These capabilities are essential for customers operating in regulated industries where precision and reliability are critical. ISO 13485 Injection Molding for Medical and Microfluidic Applications ISO 13485 injection molding provides a controlled quality management framework for manufacturing components intended for medical and other regulated applications. At Micromolds, this framework supports our micro injection molding processes, where component geometries can reach micron-level dimensions and even minimal deviations may affect product performance. ISO 13485 certification enables Micromolds to better support: Medical device manufacturers Microfluidic chip developers Advanced diagnostics and lab-on-chip solutions. By aligning manufacturing processes with internationally recognized standards, the company ensures a higher level of confidence for its global partners. Strengthening Foundations for Future Growth The renewal reinforces Micromolds’ ongoing development and supports its expansion into international markets requiring strict regulatory compliance. The company continues to invest in: High-precision tooling and micro-scale manufacturing technologies Process optimization and validation Long-term partnerships with engineering-driven organizations. About Micromolds Micromolds is a precision manufacturing company specializing in micro injection molding, tooling, and high-precision polymer components for medical, microfluidic, and electronics industries. Visit micromolds.eu/about-us for more information.

Microfluidic technologies are transforming modern diagnostics, biotechnology, and analytical chemistry. Many of these systems rely on microfluidic chips containing microscopic channels that guide small volumes of liquids for chemical reactions, biological assays, or sample analysis. As microfluidic products move from laboratory prototypes to commercial applications, manufacturers face a key challenge: how to produce microfluidic devices at industrial scale while maintaining micro-scale precision. Microfluidic injection molding has emerged as one of the most effective solutions for mass-producing polymer microfluidic devices. The process combines the scalability of plastic injection molding with the precision required to replicate microscopic features such as microchannels, reaction chambers, and microstructures. For applications such as medical diagnostics and disposable analytical cartridges, this manufacturing approach offers a combination of precision, repeatability, and cost efficiency. Injection-molded polymer microfluidic chip with integrated microchannels Why Injection Molding is Used for Microfluidic Devices Many early microfluidic systems were manufactured using materials such as silicon or glass. While these materials offer excellent chemical and thermal properties, they are often expensive and difficult to scale for mass production. Polymer microfluidic devices offer several advantages: lower manufacturing costs scalable mass production compatibility with disposable diagnostic devices high replication accuracy for microstructures Injection molding is particularly attractive for microfluidic manufacturing because it allows large production volumes with consistent part quality. For disposable medical devices, this is critical. Many diagnostic systems require single-use cartridges to prevent cross-contamination and ensure accurate results What Makes Microfluidic Injection Molding Challenging Although injection molding is widely used in plastic manufacturing, producing microfluidic devices introduces additional engineering challenges. Microfluidic chips often contain microchannels with dimensions between a few micrometers and several hundred micrometers. Replicating these structures reliably requires careful control of tool design, material properties, and process parameters. Some of the most important challenges include: filling extremely small cavities preventing premature polymer solidification avoiding deformation during demolding maintaining tight dimensional tolerances One important phenomenon observed in micro injection molding is known as the hesitation effect. During filling, the polymer melt tends to flow more easily into thicker sections of the mold cavity rather than entering narrow microchannels. As a result, the polymer may fill the substrate before completely filling the microstructures. If the polymer begins to solidify before entering the microchannels, incomplete filling may occur. Understanding these micro-scale flow behaviors is essential for successful microfluidic device manufacturing. Design Guidelines for Injection-Molded Microfluidics Successful microfluidic injection molding begins with design for manufacturability. Microfluidic devices must be designed so that their microstructures can be replicated and demolded without damage. Several key design considerations are important. Shrinkage and Shape Stability Polymers shrink as they cool after injection molding. This shrinkage can cause dimensional changes or warpage in the molded part. For microfluidic chips, maintaining flatness and dimensional stability is particularly important because many devices require precise bonding between a microstructured substrate and a sealing layer. Shrinkage can be controlled through: optimized process parameters careful material selection mold design considerations Draft Angles for Demolding Draft angles help ensure that molded parts can be removed from the mold without damaging microstructures. For microfluidic structures, even small draft angles can significantly improve demolding performance. In many micro-injection molding applications, draft angles greater than approximately 0.25° are recommended. Minimum Channel Dimensions The minimum achievable microchannel size depends on several factors: mold manufacturing precision polymer flow behavior injection pressure and temperature Experimental studies have shown that injection molding can replicate structures in the sub-micrometer range under optimized conditions. However, practical microfluidic channel dimensions typically range from 10 µm to several hundred micrometers. Aspect Ratio Limits The aspect ratio of microstructures plays a critical role in mold filling and demolding. High aspect ratio microchannels are more difficult to fill and may trap air or solidify before complete filling occurs. In microfluidic injection molding, achievable aspect ratios depend on material properties, tooling precision, and process conditions. In most practical applications, aspect ratios typically range from 1 to 5, while values up to around 10 can be achieved under optimized conditions. Higher aspect ratios are generally limited to specialized cases and may increase the risk of incomplete filling, air trapping, or deformation during demolding. Tooling Technologies for Microfluidic Injection Molding The precision of microfluidic injection molding is determined largely by the quality of the microfluidic mold tooling. Microfluidic devices contain micro-scale channels, mixers, and reaction chambers that must be replicated with extremely high fidelity. Even small deviations in tooling precision can affect fluid behavior inside microchannels, making tool manufacturing one of the most critical stages in microfluidic device production. Depending on the development stage of the device and production volume, different tooling approaches are used. Precision steel molds for microfluidic injection molding Rapid Tooling for Microfluidic Prototyping During the early stages of microfluidic product development, rapid tooling is commonly used to validate device designs using real injection-molded materials. Unlike microfluidic prototyping methods such as soft lithography or 3D printing, injection-molded prototypes allow engineers to evaluate how the device will behave under actual production conditions. Rapid tooling is applied for: validating microfluidic channel geometry testing fluid flow behavior in molded polymers producing small pilot batches bridging the transition from prototyping to serial production Because rapid tooling requires lower investment and shorter lead times, it enables faster design iteration during early product development. Laser-Machined Precision Tooling Laser micromachining is widely used for producing high-precision mold inserts required for microfluidic device manufacturing. Laser machining enables the fabrication of detailed microstructures such as: microfluidic channels mixers and flow distributors reaction chambers micro-scale surface structures This technology is particularly useful when complex geometries must be produced with tight tolerances and smooth surface finishes, both of which are important for consistent microfluidic flow. Laser-machined tooling can also support relatively fast design iterations during the product development phase. LIGA Tooling for High-Aspect-Ratio Microstructures Certain microfluidic applications require extremely fine structures or high-aspect-ratio features that are difficult to manufacture using conventional machining methods. In these cases, LIGA tooling can be used to produce mold inserts with highly precise microstructures. The LIGA process combines lithography and electroforming to create metallic microstructures with: very high dimensional accuracy smooth vertical sidewalls high aspect ratio capabilities This approach is suitable for microfluidic components used in advanced analytical devices, biosensors, and high-precision diagnostic systems. Materials Used in Microfluidic Injection Molding Material selection is an important factor in both device performance and manufacturability. Several thermoplastic polymers are commonly used for microfluidic applications. PMMA (Polymethyl Methacrylate) PMMA offers excellent optical transparency and is widely used in microfluidic devices that rely on optical detection. Polycarbonate (PC) Polycarbonate provides strong mechanical properties and good dimensional stability. Cyclic Olefin Copolymer (COC) COC is frequently used in medical microfluidic devices due to its optical clarity and chemical resistance. Process Parameters in Microfluidic Injection Molding Producing high-quality microfluidic components requires careful control of injection molding parameters. Important parameters include: melt temperature mold temperature injection speed injection pressure holding pressure cooling time Among these, mold temperature and injection speed are often the most critical parameters for achieving complete filling of microstructures. Some advanced systems use variothermal molding, where the mold is heated during injection and cooled during solidification. This approach helps prevent premature polymer freezing while maintaining reasonable cycle times. From Prototype to Production Microfluidic technologies are rapidly expanding across diagnostics, biotechnology, and analytical systems. As microfluidic products move from laboratory concepts to real-world applications, robust manufacturing methods become increasingly important. Microfluidic injection molding offers an effective solution for producing polymer microfluidic devices with high precision and repeatability. By combining optimized mold design, material selection, and controlled process parameters, manufacturers can replicate complex microstructures such as microchannels, mixers, and reaction chambers. However, successful microfluidic manufacturing requires close collaboration between product designers, tooling engineers, and injection molding specialists. Design decisions such as channel geometry, aspect ratio, and material selection directly influence manufacturability and final device performance. For companies developing microfluidic chips or microfluidic devices, understanding these manufacturing constraints early in the design process can significantly reduce development time and production risks. Not Sure if Your Design Is Ready for Injection Molding? If your device has been validated and you are preparing for thermoplastic production, explore our microfluidic injection molding capabilities or send us your CAD file for a manufacturability review. Frequently Asked Question Can my microfluidic design be injection molded? Most microfluidic devices can be adapted for injection molding, but channel geometry, aspect ratio, materials, and tolerances determine manufacturability. An early DFM review helps identify potential risks before tooling begins. What is the minimum channel size for injection molding? Depending on the application and tooling technology, injection molding can replicate microchannels from approximately 10 µm upwards, with even smaller features possible in specialized cases. Which materials are best for microfluidic injection molding? Common materials include COC, COP, PMMA, Polycarbonate (PC), and Polystyrene (PS). The optimal choice depends on optical requirements, chemical compatibility, sterilization, and the intended application. How much does a microfluidic mold cost? Tooling costs depend on part complexity, tolerances, material, and expected production volume. Rapid tooling offers a cost-effective option for validation before investing in serial production tooling. Can I test my design before investing in production tooling? Yes. Rapid tooling allows manufacturers to produce functional injection-molded prototypes for testing, validation, and pilot production before committing to a production mold. What information do you need for a feasibility review? A CAD file (STEP preferred), application details, material requirements, expected production volume, and any critical tolerances help engineers evaluate manufacturability and recommend the best production approach. How long does a manufacturability review take? Most feasibility reviews can be completed within a few business days, depending on the complexity of the project and the information provided.

Microfluidic product development plays a critical role in modern diagnostics, life sciences, and analytical systems, enabling the creation of compact devices that precisely control small volumes of fluids for testing, detection, and processing. Manufacturability in microfluidic product development is determined by how well channel geometry, material behavior, bonding strategy, and process constraints are aligned with real manufacturing conditions. These include factors such as injection molding flow behavior, thermal gradients, and tooling limitations, all of which directly impact whether a design can be produced reliably. Developing a working microfluidic concept is only part of the challenge. The real difficulty begins when a design must transition from a functional prototype to a manufacturable product. Understanding these constraints early allows engineering teams to avoid delays, redesign, and unnecessary cost. What Is Microfluidic Product Development Microfluidic product development is the process of turning a concept into a production-ready device. It typically involves: validating fluid behavior and functionality developing channel geometry and layout selecting suitable materials aligning the design with manufacturing methods Unlike general product development, microfluidics operates at micro-scale precision. Even small variations in geometry or material behavior can affect performance, making early design decisions critical. For a broader overview of technologies and applications, see our microfluidics hub. How Microfluidic Development Works in Practice Most microfluidic projects begin with microfluidic prototyping methods such as PDMS casting, CNC machining, or additive manufacturing. These approaches allow rapid iteration and functional validation. At this stage, the focus is on: flow behavior geometry validation experimental flexibility As development progresses, priorities shift toward: dimensional stability material behavior repeatability production feasibility This transition from microfluidics fabrication to manufacturing is where many projects encounter limitations. Prototypes validate function, but they do not necessarily validate manufacturability. When Development Becomes a Manufacturing Challenge Microfluidic development becomes a manufacturing challenge when the design must operate within physical and process constraints. Common issues include: microchannel geometries that cannot be filled consistently below ~50 µm high aspect ratio structures (>5:1) leading to incomplete filling or breakage material behavior that changes under molding temperatures and pressures bonding methods that reduce yield due to leakage or deformation dimensional instability caused by shrinkage (typically 0.5–1.5% depending on polymer) These issues are typically the result of design decisions made without considering real manufacturing conditions. In microfluidic injection molding, replication fidelity is determined by the interaction between melt rheology, thermal gradients, and cavity geometry. Microchannels with high aspect ratios or abrupt transitions increase the likelihood of hesitation flow, where the polymer preferentially fills thicker regions before entering micro-scale features. This can result in incomplete channel filling, air entrapment, and dimensional deviations in the range of several micrometers. As a result, designs that appear correct during prototyping often fail during production. At micro-scale, physical effects that are negligible in early-stage validation become dominant and directly impact manufacturability. When Injection Molding Becomes the Right Choice For applications requiring repeatability, precision, and cost control, injection molding is often the preferred manufacturing method, both for low-volume pilot runs and high-volume production. It enables: consistent replication of micro-scale features down to ~10–50 µm tight dimensional tolerances typically within ±5–10 µm compatibility with microfluidic materials such as COC, COP, and PMMA However, injection molding introduces strict constraints. Designs must account for: polymer flow behavior at micro-scale demolding requirements such as draft angles (typically ≥0.25°) venting and air evacuation in micro-scale cavities tooling precision and surface quality At micro-scale, polymer flow becomes highly sensitive to cavity geometry and thermal conditions. Variations in mold temperature, injection speed, or venting can lead to incomplete filling of microchannels, surface defects, and reduced replication accuracy. Because of this, transitioning to injection molding is not simply a production step. It is a design validation stage where manufacturability is confirmed under real process conditions. Benefits of Aligning Development with Manufacturing Early When manufacturability is considered early, development becomes more predictable and efficient. Key benefits include: reduced risk of redesign before tooling shorter development cycles improved consistency in production better cost control across volumes By aligning prototyping, materials, and design with manufacturing constraints, teams ensure that early validation reflects real production conditions. What Determines Manufacturability in Microfluidic Product Development Microfluidic manufacturability is determined by how well key design and process factors are aligned with real manufacturing conditions. These include: channel geometry compatible with replication limits material behavior under molding conditions bonding strategy that supports repeatability process constraints such as flow behavior, temperature control, and tooling precision A design that meets these criteria can be produced reliably. A design that does not will typically require redesign before production. Not Sure if Your Design Is Ready for Injection Molding? Upload your CAD file or describe your device. We'll review it and send you a feasibility report and quote. Frequently Asked Questions What is microfluidic product development? Microfluidic product development is the process of transforming a functional device concept into a manufacturable product. It involves design validation, material selection, and alignment with scalable production methods. When does a microfluidic design become difficult to manufacture? A design becomes difficult to manufacture when geometry, materials, or bonding methods are not compatible with production processes such as injection molding. This often leads to incomplete feature replication, deformation, or inconsistent quality. Can microfluidic devices be produced in low volumes? Yes. Microfluidic devices can be produced in both low-volume pilot runs and high-volume production. The choice depends on the development stage, required precision, and cost considerations. Do prototypes behave the same as production parts? Not always. Prototypes made from PDMS or machined materials may behave differently than injection-molded thermoplastic parts due to differences in material properties and manufacturing conditions. When should manufacturability be evaluated? Manufacturability should be evaluated as early as possible, ideally during the design or prototyping phase. Early evaluation helps avoid redesign and reduces production risk.

Project Requirements The chip architecture imposed strict technical requirements: Microchannel geometry with tight dimensional tolerances and no draft radius compensation Optical clarity for accurate signal detection, including in bonding-affected regions Dimensional stability after bonding PMMA-to-PMMA bonding without microchannel deformation At this scale, tool design, microchannel size and density, combined with material processing conditions, can result in incomplete filling, air entrapment, or dimensional deviation. Engineering Approach Micromolds aligned the design with manufacturing constraints from the earliest stages. Key activities included: Development of high-precision tooling using diamond-tipped cutters and advanced CNC micro-milling for accurate microchannel replication Design-for-manufacturing (DfM) adjustments to improve polymer flow and demolding behavior Material selection based on optical, mechanical, and bonding requirements Validation of molding and bonding process parameters to ensure dimensional control Sample approval with the client prior to production transition Process conditions were optimized to manage polymer flow, thermal gradients, and cavity filling behavior, all critical for reliable microfeature replication. At micro-scale, flow imbalance between thick sections and microchannels can cause hesitation effects, making geometry and process alignment essential for complete filling. PMMA-to-PMMA bonding required the development of a new technological process. The key challenge was achieving a strong, optically clear bond without collapsing microchannel geometry, a common failure mode with standard thermal bonding approaches. The developed process delivers fast cycle times, preserves microchannel geometry, and is cost-efficient for large-volume production. Transitioning Microfluidic Chip Manufacturing to Production Scale Following process validation and sample approval, the design was transferred to injection molding production. Tool surface quality was maintained using diamond-tipped cutters and CNC micro-milling to meet the optical transmission requirements of the detection zone. Standard process controls ensured dimensional stability through the full production cycle: Shrinkage and warpage compensation to maintain microchannel tolerances Demolding optimization to prevent feature distortion on thin-wall geometries Bonding process alignment to preserve channel integrity at production volumes Process Stability and Repeatability Production performance was achieved through controlled and repeatable processing conditions. Key factors included: Stable temperature and injection parameters Precision tooling and surface quality control Effective venting and air evacuation Continuous monitoring of feature replication Bonding process parameter control to ensure consistent channel integrity across batches Manufacturing Outcome The result was a stable and repeatable process capable of producing a PMMA-based microfluidic chip at production scale. Micromolds achieved reliable replication of micro-scale features while maintaining the dimensional stability required for bonding and device performance. The established process enabled: Consistent feature replication across batches Reduced defect rates Stable production window Predictable manufacturing output The design was successfully transferred into production without redesign, supporting integration into a commercial diagnostic system. Bring Your Microfluidic Device to Production Micromolds supports companies developing microfluidic devices that require precise and reliable manufacturing. If your project is moving from prototyping to production, manufacturability must be evaluated early to avoid redesign and ensure stable output. Not Sure if Your Design Is Ready for Injection Molding? Upload your CAD file or describe your device. We'll review it and send you a feasibility report and quote. Production-scale PMMA microfluidic chip for point-of-care diagnostic systems. Frequently Asked Questions What microchannel geometries can you manufacture? We work with a range of microchannel geometries, including straight channels, serpentine paths, and chamber-based architectures. Channel dimensions, wall thickness, and aspect ratios all affect filling behaviour and demolding. We evaluate these early to flag any risks before tooling. Does channel geometry affect microfluidic chip bonding? Yes. Channels with very thin walls or high aspect ratios are more susceptible to deformation during bonding. Our bonding process was specifically developed to preserve microchannel geometry, but geometry review is part of our standard DfM process. What are the minimum feature sizes in microfluidic chip manufacturing? We replicate features in the range of tens to hundreds of microns. The practical minimum depends on aspect ratio, material, and channel density. If you're unsure whether your design is within range, our engineering team can assess it before you commit to tooling. Can you work with designs that weren't originally intended for injection molding? Yes — this is common. Designs created for soft lithography or machined prototypes often need DfM adjustments for injection molding. We identify and resolve these issues during the engineering phase. When should I involve a manufacturer in microfluidic chip development? As early as possible. Geometry changes after tooling are costly. Involving us at the design stage avoids redesign and accelerates the path to production. Conclusion In conclusion, Micromolds is dedicated to supporting the needs of companies developing microfluidic devices. Our expertise in manufacturing processes ensures that your designs can be effectively translated into production-ready components. By engaging with us early in your project, you can mitigate risks and enhance the manufacturability of your designs. If you are ready to take the next step in your microfluidic project, I encourage you to reach out. Together, we can bring your innovative designs to market efficiently and reliably.

Uniweb – a leading partner in Healthcare and Life Sciences of world-class innovative digital solutions that improve quality of life for their patients. Uniweb collects and processes clinical data in a regulatory and compliant way with the use of EDC solutions, Clinical Data Management, ePRO and registries systems. The company also develops its own healthcare apps and devices. Even though Uniweb’s main focus is in IT sector, this time, company has stepped into the world of hardware. Together with a consortium of Radboudumc university and ZGT Academy the team of engineers and medical students develops a medical device to measure the strength of a grip of elderly people. Low-volume injection molding for clinical tests Much research and many prototypes has been developed before Uniweb first contacted our company. It was instantly clear that the team has already put much effort in this project as the RFQ received was very informative and straight to the point. Despite that, 3D printing technology is very different from injection molding and this meant that some of the printed prototypes had to be optimised for low-volume injection molding. We had to know the critical dimensions that must remain the same in order to not disrupt the whole assembly and we successfully did that. The device itself had many plastic components which were perfect for our micromolding technology in respect of a lead time and costs of tooling. This is the main reason why we have received the contract from the client. However, because of the confidentiality issues we cannot disclose all of the information. The elastomer tube The first component that we had to mould was a tube with 2 outlets and 1 inlet. Not surprisingly, it was the most difficult too. To shape out all of this tubing we had to use 3 sliders with moving pins which had to be precision machined to enclose the whole internal channelling system. We used aluminium for the mold core and cavity and steel for the precision inserts. We delivered the project in 3 weeks with successful tube samples and were confirmed to continue with the next device components. We are proud that we can share our knowledge and contribute to the development of geriatric devices for elderly people. Soon be updated...

SUSHI Bikes GmbH It is not the sushi you may instantly think of. It is an e-bike that was developed and designed to cut an average e-bike cost by half - to just 999EUR. SUSHI bikes is a young growing start-up company disrupting e-bikes industry by taking not only a green approach to the mobility and the future but also to the manufacturing and sourcing of the bike’s components. How otherwise they could cut those costs so considerably without losing bikes’ quality? Since here at Micromolds not only do we cut molding costs twice too but we also help companies to fill the market gaps caused by demand fluctuations and bridge manufacturing from low to medium size production. We believe that our cooperation with SUSHI bikes very much relates with their overall objectives. This time we helped this company to develop and manufacture an AirTag holder which can be easily attached underneath the saddle. Design for manufacturing (DFM) As every molding project begins with DFM this was no different and we immediately started moldability analysis and part optimization for injection molding. Mainly we did these changes: 1. Draft angles have been added to the parts. 2. Some areas have been hollowed out to make walls of uniform thickness. This was done to prevent certain areas from sink marks, voids and distortions. Nevertheless, there were still remaining some places where we could not make a uniform wall thickness without changing the part’s geometry. So, we ran a moldability analysis and images were provided to see which places might be at risk of having those defects. 3. Logo has been extruded out instead of cut out to enable surface finish on flat surfaces. 4. Some walls have been pushed inside 0.5mm because of impossible mold construction. 5. Some fillets were removed around the round surface because of impossible mold machining. 6. Visuals were provided to depict: parting line, injection points and locations of ejectors. Overcoming the sink marks Thanks to our smooth communication with the SUSHI bikes’ mechanical engineer Max, we had an opportunity to exchange our know-how and thus we came up with a slight design changes to reduce those sink marks marked in red. The hollowing of thick wall region was a great balance for not losing a contact surface area in the assembly but also decreasing a sink region considerably. Mold making It took us exactly 8 days to machine the molds after the DFM was confirmed. We used aluminium molds for this low-volume production batches. Polishing was required of outer plastic casing surfaces, however, machining marks were left for the inside. Both sides of the plastic AirTag holder fit in two separate micro molds having single cavity each. Overmolding (insert molding) reduced assembly time (for pressing bushings) When we were asked to also do the assembly of the plastic housing we were thinking of using a press to tight-fit the bushings. However, only after several days, still in the initial stages of the project we agreed that overmolding will be more effective solution. We had to do slight modifications to the mold during the DFM but therefore we could save assembly costs and time considerably. Injection molding, the assembly and packing We were happy that we could provide end-to-end service for our client. After samples were confirmed we finished the first batch of 1000 units in a few days. We did the manual assembly of the whole batch. We also stuck EAN code labels to the packing boxes that were provided by the client and successfully delivered project on time. In the end, What does this really have to do with the Japanese speciality - sushi? “One rolls, the other are Rolls. So who doesn't immediately think of SUSHI when they think of e-bikes?” - SUSHI Bikes - this is how we roll.