Frequently Asked Questions
Design Guidelines
What’s the feature resolution?
We do sharp features down to 1 µm every day, and can also do many sub-micron features. Please see our design guidelines for more information.
How does the precision of Edge’s process compare to microinjection molding?
Generally speaking, Edge’s process is as precise or more precise than micromolding, when it comes to sharpness and accuracy of microfeatures. We are also far better at producing flat parts, particularly those that are thinner or have a larger footprint.
How large can the feature aspect ratio be?
For most geometries, an aspect ratio of 4-to-1 to 6-to-1 is a reasonable upper limit. This means that the height or depth of a feature can be in the range of 4 to 6 times larger than its width or diameter. There are certain geometries where we can achieve aspect ratios as high as 10-to1 or even 20-to-1.
Are draft angles required?
No, because our tooling has a compliant aspect, no draft angles are needed on any features, for both the macro-scale and micro-scale. However, including draft can improve per-part costs in some cases.
Can I have a negative draft angle on some features?
Yes, we’re able to accommodate negative draft angles on some features, in particular where O-rings or other soft materials can be added to the surface of a part.
Can you add electrodes to embossed parts?
No, this isn’t a service we’re offering at this time.
Can you embed glass windows, filters, or other external elements into finished microfluidic cartridges?
Yes, there are numerous approaches we can use to incorporate such elements.
Do you have limitations on part thickness?
Our standard part thickness is 1 mm but we can also make micro featured films in the 100 – 250 µm range, as well as very thick parts that are over 10 mm.
Materials
What materials can I choose for the final part?
We work with many common thermoplastics, including COC, COP, PMMA (acrylic), polystyrene, polycarbonate, and polypropylene. Please see our material compatibility chart for help in choosing.
Can I try different thermoplastics with the same tool?
Yes! Our process makes it easy to produce small numbers of parts in different thermoplastics.
Can I switch from PDMS to plastic while retaining certain properties?
Yes, in most cases there are suitable thermoplastics or thermoplastic elastomers (TPEs) that can replicate optical clarity at specific wavelengths, gas permeability, or deformability, and we have lots of experience helping folks transition out of PDMS. We can give you as much information as you’d like and help guide the choice towards a good long-term manufactur
Ordering
What’s the minimum order quantity?
5 parts–no matter the design. We never require you to buy a large number of parts.
Do I need to provide the microfabricated structures?
No, Edge has an extensive network of microfabrication vendors, and we will source any structures needed for your program.
But if I have an existing wafer or other microstructured part, can we use it to start the process?
In most cases, yes, we can use your existing microfabricated structure as the starting template for our process. We can use etched silicon or glass, patterned photoresist (such as SU8), machined metal or plastic, soft materials (such as PDMS), and even plastic parts made by another method, such as injection molding or hot embossing.
Services
Is your service meant for prototyping, or for manufacturing?
Both! Our tooling technology allows us to rapidly produce high-quality parts, and as soon as you’re ready, we can immediately put a production program in place and scale up the volume. You can easily test a few parts from several designs and then order large numbers of whatever design you choose.
How does Edge actually make parts—molding? Embossing? 3D printing?
We use thermal compression molding (also called thermocompression molding). Please see our process diagram for more information on how our technology works. By performing a full melt on material that starts inside the cavity, we get excellent feature reproduction without flow lines, filling issues, optical defects, and residual stresses caused by other processes.
Do you offer lidding and bonding services?
Yes! We provide both PSA lamination and thermal diffusion bonding.
Do you offer design or CAD services?
Yes, we can help with your CAD generation and design efforts if needed.
Can you manufacture parts under a quality system?
Yes, Edge maintains all requirements around facility, equipment, inventory, and documentation to implement a quality management system (QMS) for any program where needed.
What is Edge’s ISO certification status?
Currently we run ISO compliant processes in controlled areas of our manufacturing facility, and we anticipate achieving ISO13485 certification in the coming months. Please refer to our facilities section for more information.
Can my company execute a Supply Agreement or Master Services Agreement with Edge?
Yes, we routinely execute such agreements when entering formal product development and/or manufacturing with our customers.
Will Edge execute an NDA with my company?
It’s standard for Edge to execute an NDA with all customers. Even in the absence of an NDA, we keep all customer information confidential at all times, during and after programs.
How can I get fluids in and out of the finished devices?
We have a selection of standard connector ports, as well as the option to customize them to work with your inputs.
Can you ensure that the plastic disposable will interface correctly with my existing hardware?
Yes, we can apply gaskets, friction-fit ports, and numerous other types of connector to the parts, and test to ensure that they interface appropriately with your hardware.
Tooling
How many parts is the tool good for?
The short answer: there is no limit.
The longer answer: our tooling works differently from most other processes. We don’t create a single tool, but rather a multitude of identical tools, each of which has been qualified using precision metrology. Any time a produced part falls outside of specifications, the tool used is retired and immediately replaced.
Will the tool dimensions change or wear out over time?
No, because we immediately replace any tool copies that fall outside of specification, part dimensions remain faithful to the original for the lifetime of your program, even into many millions of pieces.
What are the chances my program will have a delay due to tool damage?
Zero chance. Because we pre-qualify many copies of the tool, any damaged tool is immediately replaced the same day. There is never any downtime waiting for repairs.