Abstract: A method for forming a part in an injection mold, includes: heating a molding material to a molding temperature; injecting the molding material through a gate and into a molding cavity of the injection molding apparatus of any of the preceding claims; pressing the stationary half and the moving half together to form the molding cavity between the resin mold surface and the insert molding surface; moving the movable mold insert, and thereby moving the insert molding surface and adjusting the molding cavity shape, the molding cavity depth, the molding cavity volume, or a combination comprising at least one of the foregoing along at least a portion of the molding cavity; cooling a surface of the molding cavity with the cooling system; separating the resin mold surface and the moving half mold surface; and ejecting the part from the injection molding apparatus.

Abstract: A method of injection molding parts, including: injecting a first thermoplastic polymer into a first cavity; forming a ribbed structure comprising ribs in the first cavity, wherein each rib in the ribbed structure includes a microstructure on an outer portion of a rib; and reducing the surface imperfections in the part by overmolding a layer formed in the second cavity onto a portion of a rib by injecting a second thermoplastic polymer into the second cavity, wherein the overmolding occurs at an interface between the layer and the ribbed structure; or injecting a first thermoplastic polymer into a first cavity; forming a layer in the first cavity; and overmolding a ribbed structure comprising ribs formed in the second cavity onto a portion of the layer formed in the first cavity. In further variations gas is injected into a microchannel formed at the interface or a foaming agent is applied in the first thermoplastic polymer.

Abstract: Disclosed herein are microfluidic devices formed using a process comprising the step of disposing a planar barrier adjacent a surface of a molded base layer and positioned to overlay at least a portion of a microchannel provided therein, as well as lab on a chip device comprising: a base layer, a sensor disposed adjacent a first surface of the base layer, a cover layer disposed adjacent the first surface of the base layer to at least partially cover the sensor and a hesitation molded closing layer disposed on a second surface of the base layer opposite the first surface of the base layer, wherein the closing layer encloses at least a portion of the microchannel.

Abstract: Disclosed herein are methods for manufacture of microfluidic devices on a single injection molding machine to provide a ready-to-use microfluidic device, such as a “lab on a chip” device. In particular, it refers to a molding method comprising the step of disposing a planar barrier adjacent to a surface of the base layer and positioned to overlay at least a portion of the microchannel; and causing a material to be disposed on the base layer using hesitation injection molding to create a closing layer configured to overmold at least a portion of the planar barrier and a least a portion of the microchannel. It further refers to a method comprising the step of disposing a sensor adjacent a first surface of the base layer and molding a cover layer adjacent the first surface of the base layer to at least partially cover the sensor and to secure the sensor in position relative to the base layer.

Abstract: A method of injection molding parts, including: injecting a first thermoplastic polymer into a first cavity; forming a ribbed structure comprising ribs in the first cavity, wherein each rib in the ribbed structure includes a microstructure on an outer portion of a rib; and reducing the surface imperfections in the part by overmolding a layer formed in the second cavity onto a portion of a rib by injecting a second thermoplastic polymer into the second cavity, wherein the overmolding occurs at an interface between the layer and the ribbed structure; or injecting a first thermoplastic polymer into a first cavity; forming a layer in the first cavity; and overmolding a ribbed structure comprising ribs formed in the second cavity onto a portion of the layer formed in the first cavity. In further variations gas is injected into a microchannel formed at the interface or a foaming agent is applied in the first thermoplastic polymer.

Abstract: A method for forming a part in an injection mold, includes: heating a molding material to a molding temperature; injecting the molding material through a gate and into a molding cavity of the injection molding apparatus of any of the preceding claims; pressing the stationary half and the moving half together to form the molding cavity between the resin mold surface and the insert molding surface; moving the movable mold insert, and thereby moving the insert molding surface and adjusting the molding cavity shape, the molding cavity depth, the molding cavity volume, or a combination comprising at least one of the foregoing along at least a portion of the molding cavity; cooling a surface of the molding cavity with the cooling system; separating the resin mold surface and the moving half mold surface; and ejecting the part from the injection molding apparatus.

Abstract: A molding system (10) for fabricating a part comprises a first mold section (12) defining a first mold cavity (14), a first insert (16) slidable to a plurality of positions relative to the first mold cavity (14) to adjust a dimension of the mold cavity, a second mold section (20) to be disposed adjacent to the first mold section (14) to at least partially enclose the first mold cavity (14), a molding material conduit (26) to be disposed in fluid communication with the first mold cavity (14), and a positioning mechanism (18) configured to move the first insert (16) to the plurality of positions relative the first mold cavity (14).

Abstract: A layer multiplier (100) is disclosed. It comprises an inlet (102) for a flow of multilayered flowable material, a distribution manifold (104) into which the inlet debouches, a number >2 of separate splitting channels (106) extending from the distribution manifold, a recombination manifold (108) into which the splitting channels debouch, an outlet in one end of the recombination manifold, and the distribution manifold is arranged in an opposing relationship with the recombination manifold.

Abstract: A layer multiplier (100) is disclosed. It comprises an inlet (102) for a flow of multilayered flowable material, a distribution manifold (104) into which the inlet debouches, a number>2 of separate splitting channels (106) extending from the distribution manifold, a recombination manifold (108) into which the splitting channels debouch, an outlet in one end of the recombination manifold, and the distribution manifold is arranged in an opposing relationship with the recombination manifold.