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Microreplication

In-house Microreplication of Low and High Aspect Ratio Microstructures as Thin as 50micron.

Microreplication, Microembossing - Custom Microstructure Production and Manufacturing

Microreplication technology produces high aspect ratio precision microstructured geometries in a variety of polymer films, widely used in medical, optics, and biotechnology fields. Producing high aspect ratio precision microstructures is a complex multi-step process that involves masking, tooling, mastering and microembossing. There are usually several iterations in the microstructure design and compromises need to be made between desired geometry of the structure and ability of the pattern to be accurately replicated.

We typically work with polycarbonate (PC) and polyetherimide (PEI) as thin as 50micron. We have hands-on materials and microembossing expertise to develop a specific microreplication process for a polymer of your choice. We regularly make microreplications of greater than 5:1 aspect ratios and ~250k features per square inch. We can achieve high aspect ratio microreplications of greater than 10:1 on smaller scale samples.

Cospheric offers microstructure pattern design and materials development, process development, and small-scale microembossing for product design and testing. When your product is ready for manufacturing, we will work with our partners to scale up replication of your pattern up to 1.5m x 2m. We can also apply precision thin coatings on microstructures, and have extensive experience with optically-clear laminations, encapsulations and adhesives.

Coated Microstructures - Achieve precision thin functional coatings as thin as 1 micron on microstructure of your choice.

Coated Microembossed Microstructure with Cavities or Pockets
Our coating process is not limited to small particles. Just as easily, we can coat microstructures to have a different functionality on one surface. For example, you might need the top surface of your structure to have a different color, charge, or surface properties, but do not want to block open channels, vias, and cavities, or restrict the movement of fluids. You might need a coating precise enough to work with 10micron features. Cospheric has a solution. The coating is applied to the top surface. It does not interfere with the geometry of microstructures or block channels and cavities. The exact coating formuation is developed per individual customer specifications. We currently have functional coating formulations for coating on glass, metal, hydrophobic and hydrophilic polymers. Our functional coatings are resistant to most solvents and harsh environments.
Opaque Microcoating on Microembossed Structure with Channels
The coating is applied to the top surface. It does not interfere with the geometry of microstructures or block channels and cavities. The exact coating formuation is developed per individual customer specifications. We currently have functional coating formulations for coating on glass, metal, hydrophobic and hydrophilic polymers. Our functional coatings are resistant to most solvents and harsh environments. In pictures above cavities are around 50micron in diameter and 80micron deep.

Contact us to discuss your particular application and to design precision microstructure for your product. We have short lead times and cost-effective R&D process.