MANUFACTURING
Hot Embossing for Microfluidic Chips
Hot embossing stamps microfluidic channels into plastic by pressing a heated mould into a softened thermoplastic sheet. It sits between prototyping and full injection moulding. Here is how it works and when to use it.
What is hot embossing?
A thermoplastic sheet — such as COC, COP or PMMA — is heated near its glass-transition temperature, then a mould bearing the inverse of the channel pattern is pressed in under controlled force. On cooling and de-moulding, the channels are replicated in the plastic.
Where it fits
- Low-to-medium volume — cheaper tooling and setup than injection moulding.
- High fidelity — gentle flow replicates fine features and high aspect ratios well.
- Bridge step — useful between CNC prototypes and full injection moulding.
Trade-offs vs injection moulding
Hot embossing has longer cycle times (minutes vs seconds) so it is slower at high volume, but its lower tooling cost and gentle replication make it attractive for pilot runs and delicate features. Embossed parts still need bonding to seal the channels.
Frequently asked questions
What is hot embossing?
A replication method that presses a heated mould into a softened thermoplastic sheet to form microfluidic channels, then cools and de-moulds the part.
When is hot embossing used instead of injection moulding?
For low-to-medium volumes and delicate, high-aspect-ratio features, where its lower tooling cost and gentle replication outweigh its slower cycle time.
What materials can be hot embossed?
Thermoplastics such as COC, COP and PMMA are commonly used.
Replicate without big tooling
Need pilot-volume chips?
We advise on embossing vs moulding and manufacture either way. Upload your design for a quote, or book a call.
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