When viewed in cross-section, the aspect ratio of a molded microfeature is the ratio of its height (H) to width (W). This aspect ratio is an important parameter that will inform the rest of a device’s design constraints. Keeping the molded microfeatures within the listed aspect ratio guidelines close to 1:1 whenever possible often leads to the most consistent results.

All molded microfeatures must have draft – a slight taper to the microfeature walls that allows the part to eject safely after molding. The width (W) measures the widest point of the molded microfeature.

Following the minimum and maximum molded microfeature sizes below will guarantee your design is ready for transition molding. Don’t hesitate to reach out to engineering if you need features outside of the suggested range. In most cases, we can stretch beyond the guidelines for specific applications.

All molded microfeatures must have a draft. The width (W) shown above measures the widest point of the molded microfeature. The height (H) of a molded microfeature must not exceed 50% of the fluidic layer thickness (Z).

You can create microfeatures with design freedom in three dimensions with Transition Molding – tapered surfaces, varying heights, and domed features are all possible.

Corner radii are critical to ensure your design is ready for Transition Molding. Avoiding unnecessarily small corner radii and minimizing the aspect ratio of the corner radius (R) to molded microfeatrure height (H) will reduce project cost and lead to consistent molding results.

If the device is capped, all molded microfeatures must be at least 1.5 mm from the outer perimeter of the fluidic layer.

All molded microfeatures must be separated by at least 300 µm at the narrowest point.

All molded microfeatures must have a draft. The final outcome will fall within our tolerances: