Photolithography transfers the desired microscale design onto a substrate coated with a photoresist such as SU-8. A photomask controls where exposure occurs, and development reveals the patterned resist. This sequence establishes the locations and shapes of channels, chambers, and other raised features that will be reproduced during later molding.
Raised structures provide the physical relief needed to form recessed channels and chambers in a replica material. Their arrangement determines the geometry of the resulting fluidic network, including where fluid can be guided or contained. Because the master serves as the template for replica molding, its patterned features support reproducible production of microfluidic devices.
The master mold contains the patterned raised structures, whereas the PDMS replica receives the corresponding recessed features after casting and curing. The mold therefore functions as the template, while the replica becomes the patterned device component. Bonding that replica to a substrate produces the assembled structure used for microfluidic experiments.
A typical workflow coats a substrate with SU-8 or another photoresist, exposes it through a photomask, and develops the patterned layer to create raised features. Researchers then cast PDMS over the master, cure the material, and bond the patterned replica to a substrate. This sequence converts a designed pattern into a usable microfluidic device.
The principal materials and elements are a substrate, a photoresist such as SU-8, a photomask, PDMS, and a bonding substrate. The photoresist and mask establish the master pattern, while PDMS captures that relief during casting and curing. Together, these components support repeated fabrication of devices with defined microscale fluidic features.
Devices produced from these molds support lab-on-a-chip systems for cell culture, tissue engineering, diagnostics, and drug testing. They also enable studies of fluid flow in biological microenvironments. In each case, the patterned channels and chambers provide a controlled microscale setting for handling fluids or examining biological processes relevant to engineering and biomedical research.