Abstract
A new rapid prototyping method is reported. It is based on injection molding with inexpensive mold inserts, 3D-printed in durable polymer-based materials. The method allows for manufacturing of microfluidics in common thermoplastics materials at a lower cost and with shorter lead-times compared to injection molding with conventional metal inserts. Up to about 100 parts can currently be molded from a single 3D-printed insert without deterioration of the insert. The smallest feasible design feature is ca 100 μm with the 3D-printing machine used in this study. The molded parts are transparent and have a surface finish suitable for various microfluidics applications.