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February 17, 2026Open Access

Polymer Micro-Milling for Cost-Effective Microfluidic and Biosensor Chip Fabrication: A Review

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Authors

ATArjun ThakurSPShreeji PanditASAbhishek Singh

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Overview

This review demonstrates micro-milling's effectiveness for producing biosensor chips, indicating broader applications in diagnostics.

Key Points

  • This review aims to evaluate polymer-based micro-milling as a novel method for microfluidic device fabrication.
  • Analysis of traditional fabrication techniques like photolithography and soft lithography
  • Focus on advancements in polymer-based micro-milling technology
  • Examination of critical parameters affecting the quality of the fabricated devices
  • Assessment of recent progress in toolpath optimization and process monitoring
  • Micro-milling significantly improves dimensional accuracy and surface quality for microfluidic devices.
  • Challenges like tool wear and burr formation still limit reproducibility.
  • Hybrid methods show promise for overcoming existing manufacturing barriers.
  • Micro-milling is identified as a cost-effective alternative to traditional methods.

Cite This Study

Thakur et al. (2026) studied this question.

synapsesocial.com/papers/699405bb4e9c9e835dfd6907https://doi.org/10.3390/micro6010016
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