BioMEMS are compact devices which use microfabrication to miniaturize conventional benchtop instruments. The benefits of using micro devices are the need for less chemical reagents, faster processing, and portability. Realizing a powerful sample-to-answer micro system requires more than just microfabrication technology; thermal management, microfluidic control, and interfacing technology must also be considered. You et al. [1] applied kinematic constraint analysis using screw theory to design the assembly features for passive alignment structures for polymer, modular microfluidic devices. Three pairs of v-groove and hemispherical pin joints were chosen as kinematic pairs for mating two modules. Dimensional variation of the assembly features was one of principal contributions to the mismatch of 28 μm-75 μm between stacked plates in assembly that was reported. This was primarily a result of incomplete mold filling and deformation of the passive alignment structures during the demolding process. Hemisphere-tipped recesses, with additional annular walls as dummy structures, were used to designed to achieve better replication by improving polymer filling and reducing the deformation during demolding. In prototype devices, the posts with the annular dummy structures had a mean height of 922.2 μm – 924.1 μm while the original posts without dummy structures had mean heights of 865.3 μm – 891.2 μm in 10 samples under the same embossing conditions for a design height of 925 μm. Alignment accuracy of better than 10 μm was achieved in the assembly of two plates.

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