Fabrication of Genetic Analysis Microsystems using Plastic Microcasting

In this paper we present a simple, low cost, high resolution plastic microcasting method using two component, optically clear polymers for the fabrication of microfluidic systems. This method allows excellent replication of microfeatures (<1 m), low surface roughness (< 30 nm), the ability to embed devices, and the capability of mass production. Using this method we have successfully implemented plastic microsystems capable of separating and amplifying DNA. We present the first demonstration of plastic microreaction chambers with on-chip heaters and coolers and also the fabrication and demonstration of a microcapillary electrophoresis device made by this technique.