Aluminium Mould Generator

Upload your channel features as an STL file to generate a complete 4-inch (101.6 mm) circular aluminium mould. Configure the base thickness, preview in 3D, and export as a STEP file for CNC machining. Compatible with thermoplastic hot embossing workflows.

Mould Specification: 4-inch (101.6 mm) circular wafer, max total thickness 20 mm. Upload your channel features as an STL file to generate the complete aluminium mould and export as STEP.

1. Upload Features (STL)

📂Drop STL file here or click to browse.stl files only

2. Configure Mould

Base Thickness3.0 mm

3. Mould Summary

Wafer diameter101.6 mm (4")

Base thickness—

Feature height—

Total thickness—

Feature footprint—

4. Export

5. Submit Your Mould Design For Manufacture

Happy with your mould? Upload your design file and we’ll CNC-machine it in aluminium — ready for PDMS casting or hot embossing.

Upload Design for Manufacture

Privacy & SecurityAll processing happens entirely in your browser. No design files are uploaded to any server. Your STL geometry never leaves your device. The STEP file is generated locally and downloaded directly to your computer.

Upload an STL file to preview the mould

Scroll to zoom · Drag to rotate · Right-drag to pan

About Aluminium Moulds for Microfluidics

Aluminium moulds are widely used for hot embossing and injection moulding of microfluidic chips in thermoplastics such as COC, COP, and PMMA. A typical workflow starts with a CAD model of the channel features, which is then CNC-machined into the face of a precision-ground aluminium disc.

Why 4-Inch Wafer Format?

The 4-inch (101.6 mm) format is the most common standard for research-scale microfluidic fabrication. It fits standard hot-embossing presses (e.g., Eden Tech, Jenoptik) and aligns with cleanroom wafer tooling. The circular geometry ensures uniform pressure distribution during embossing.

Design Constraints

The maximum total mould thickness (base + features) is limited to 20 mm to fit standard press fixtures. The base layer provides structural rigidity and thermal mass, while the feature layer contains your channel geometry. A thicker base improves heat distribution but reduces the allowable feature height.

STL to STEP Workflow

This tool accepts STL files (the standard output from most 3D design tools and microfluidic layout software) and generates a STEP file with the complete mould geometry. STEP (ISO 10303) is the preferred format for CNC machining as it preserves exact geometry definitions rather than triangulated approximations.

Material: Aluminium 6082-T6

Aluminium 6082-T6 is the recommended alloy for microfluidic moulds. It offers excellent machinability, good thermal conductivity (170 W/m·K), and sufficient hardness for thousands of embossing cycles. For higher durability, the mould can be hard-anodised or nickel-plated.

Need a custom microfluidic mould machined?

From aluminium mould CNC machining to complete chip fabrication in COC, COP, and PMMA. Upload your design or get in touch.

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