Hybrid microstructures can now be manufactured incorporating various material elements, including metals and polymers, to produce cost-effective integrated devices for new generation applications, from life sciences to diverse micro industry needs.

Developed by leading Photo Electro Forming (PEF) specialist, Tecan, the process has huge potential and is already being used to produce structures and components, at microscopic levels, such as gear wheels, coils, encoder discs, lenses, micro filters and similar products, which may be stand-alone devices or component parts of other micro systems.

"Imagine a micro component with customised integrated layers of materials, these could include metals or polymers, maybe with electronic interconnects or micro-fluidic channels - virtually any combination of these is possible", said Nick Hollinshead, Tecan's microstructure division manager. "Alternatively, single material parts such as plastic only components can be produced. Industries already expressing interest in our technology include medical, bio-tech, IT, pharmaceutical, optoelectronics and aerospace. Designers now have the freedom to conceive innovative component solutions based on proven manufacturing techniques which assure repeatable results for highly-reliable products."

Advantages of the process include: low production costs, ultra-fine tolerances, superior surface finishes, high precision, exceptional repeatability, stress and burr free, superior co-planarity, sharp edge definition, variations in hardness, multi-level 'stepped' profiles, low tooling costs, short lead times and easy batch fabrication.

The use of new fabrication processes for polymer materials, such as SU8, will be developed further during 2005, during which time the company aims to work closely with designers and niche product developers. The goal is to continue the manufacture of micro-parts, which have gone through a process of careful product development with an evaluation of all critical parameters. The use of polymers, in particular, enables not only the manufacture of stand-alone plastic components, but also the integration of new functionality and the possibility of integration with optoelectronic and micro-fluidic devices. The manufacturing process assures the minimal tolerances at highest possible reproducibility, which is indispensable for the realisation of micro-systems. Furthermore, while taking advantage of the latest advances in polymer techniques, the new process loses none of the benefits associated with existing processes, says the company.

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