Diffusion bonding of polymer based micro- and nano-fluidic devices

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Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 35591

Start date and planned duration: August 2023, 5 months

Objective

Use TWI’s expert knowledge & experience in the field of diffusion bonding and submicron laser channelling to develop a thermoplastic demonstrator manifold with submicron/nano channels.
To develop suitable diffusion bonding and laser channelling parameters for at least 2off thermoplastic materials.
Use the demonstrators and published information to directly approach Members and to grow TWI’s activity in this area.
Use this project as a platform to diversify TWI’s involvement in this technology to other industrial applications.

Project Outline

In the proposed project work, diffusion bonding and submicron laser channelling processes for two thermoplastic substrates (preliminarily PMMA – Polymethyl methacrylate and PC - Polycarbonate) will be developed with a view of being able to manufacture novel microfluidic devices, primarily targeted at the bio-pharmaceutical industry. These microfluidic devices are expected to exhibit unique features including ultra-high surface to volume ratio, scales comparable with the range of various surface/interfacial forces and size of the important biomolecules. Laser channelling will be carried out using existing laser systems at TWI, such as nano and pico second pulsed laser sources. For the diffusion bonding process, the substrates will be placed in a vacuum furnace and joining will be accomplished by heating the assembly below the glass transition temperature, under the application of a low pressure throughout the cycle. The final phase will involve manufacturing 1off demonstrator that will be used for marketing purposes.

The project is broken down into 4 work packages as shown below:

Work Package 1 – Diffusion bonding of flat thermoplastic panels
Work Package 2 – Laser Microchannel creation in the panel and diffusion bonding
Work Package 3 - Micro channel leak testing
Work Package 4 - Project management and dissemination

Industry Sectors

- Medical

- Biological, diagonostic and Medical

- Clinical Chemistry and Pharmacy

Benefits to Industry

Introduce the novel technology to capture the medical sector which is around 20% and global microfluidics market is expected to reach ~40 billion by 2027
New SCP’s in the medical sector and attract new members to the novel technology and technical excellence of TWI to support the industry
Innovative product and potential for IP development
Offer full manufacturing support that combines both the technologies (diffusion bonding and laser machining) to the customer
Exploit plastic diffusion bonding in food industry, chemical processing, fuel injectors and microelectronics/semiconductor manufacturing
The project will result in cost reduction, quality improvement, increase in process yield and establish clean, safe and sustainable process