Sticker micromolds for low-cost rapid-fabrication of polymer and textile-based biomedical devices

In this work we present “sticker moulds” for ultra-rapid prototyping. For fabrication of PDMS devices, these moulds are comprised of a glass substrate with layers of Uline Industrial Tape S-423 patterned by laser ablation. We examine the geometry and surface roughness of these moulds and the resultant PDMS devices using microscopy and profilometry . Channels dimensions as small as 150µm wide and 50µm deep are achieved, with a W-shaped kerf. These moulds have low material cost (< 10 cents per mould), require under 10 minutes to fabricate, and have low surface roughness, resulting in smooth PDMS devices that readily bond. For devices directly printed on textiles, moulds developed from simple sticky paper can also be patterned using laser ablation, and adhered to the textile or existing ink patterns. The low barrier to entry makes sticker mould ideal for rapid proof-of-concept work where designs are frequently changing, or a classroom setting . Furthermore, we employ sticker moulds for development of electronic and microfluidic structures directly on textiles for wearable biomedical systems.