Review on ultrasonic fabrication of polymer micro devices.

Fabrication of micro devices from thermoplastic polymers by ultrasonic processing has become a promising new technology in recent years. Microstructures are generated on polymer surfaces with cycle times of a few seconds and are tightly sealed in even shorter times. Investment costs and energy consumption are comparatively low and processes are very flexible enabling economic fabrication even for small-scale production. For large-scale production role-to-role fabrication has been shown reducing costs even more. A variety of micro devices have been introduced up to now mostly for microfluidic applications. Besides this, electronic circuit boards are fabricated by ultrasonic processing.

Microsystems in medicine.

The complexity of modern surgical and analytical methods requires the miniaturisation of many medical devices. The LIGA technique and also mechanical microengineering are well known for the batch fabrication of microsystems. Actuators and sensors are developed based on these techniques. The hydraulic actuation principle is advantageous for medical applications since the energy may be supplied by pressurised balanced salt solution. Some examples are turbines, pumps and valves. In addition, optical sensors and components are useful for analysis and inspection as represented by microspectrometers and spherical lenses. Finally, plastic containers with microporous bottoms allow a 3-dimensional growth of cell culture systems.

Further development of microstructured culture systems and their use in tissue engineering.

The Forschungszentrum Karlsruhe aims at improving its CellChip. Its main feature is the 1 cm2 core, subdivided into 900 cubic microcontainers (300 x 300 x 300 microns). It is manufactured by injection molding using biodegradable (polylactide) as well as non-degradable (PMMA or PC) polymers. The CellChips will be modified such that membranes will be mounted at the bottom of the CellChip, thus facilitating backend processing. Furthermore, the membranes can be adapted ideally to the assay system of interest by various surface modification techniques.