Microfluidic Chip Bonding Services

At Creative Biolabs, our microfluidic bonding service delivers robust, clean, and long-lasting seals tailored for high-performance lab-on-a-chip manufacturing. We combine advanced surface activation, plasma bonding, thermal fusion, and adhesive-free techniques.

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Fig. 1 Simplified microfluidic system. (Wei, et al., 2005)

Creative Biolabs is dedicated to advancing microbonding technology with a focused expertise in addressing the unique challenges of microfluidic systems. Our facility supports a wide range of wafer sizes with capabilities spanning laser bonding, surface activation, and anode bonding methodologies. Our operations prioritize traceability from prototype to mass production, with a proven track record of supporting projects for leading tech firms and microfluidic device manufacturers.

Core Capabilities

Beyond standard bonding services, we offer specialized solutions tailored to diverse material and design needs.

Hybrid Material Bonding

Expertise in joining dissimilar substrates—including GaAs-SiC, InP-Diamond, and LiNbO₃-Al₂O₃—without compromising structural integrity. Ideal for microfluidic devices requiring multi-functional layers.

Ultra-Thin Wafer Handling

Precision bonding for wafers thinner than conventional limits is critical for high-density semiconductor and MEMS applications—along with miniaturized microfluidic chips and high-density channel arrays used in point-of-care diagnostics.

Hermetic Sealing

Laser-driven glass-to-glass bonding that creates gas-tight seals of extremely small volume, ideal for implantable devices and microfluidic systems handling sensitive reagents, volatile fluids, or requiring long-term storage stability.

Wafer-Level Packaging

Simultaneous sealing of numerous devices per wafer. For microfluidics, this ensures uniform microchannel dimensions across batches—a key factor in reliable fluid flow.

Technology Edge & Comparison

Our approach combines time-tested methodologies with cutting-edge innovation, outperforming traditional techniques.

Technology Our Solution Traditional Methods
Bonding Temperature Room-temperature to moderately high levels (minimizing thermal stress) Higher temperatures (risk of microchannel collapse)
Material Compatibility A broad range of substrate types optimized for fluid contact and microchannel stability Limited to silicon/glass combinations
Seal Size Down to very small scales Typically larger in volume
Additives Needed None (laser/fusion bonding, eliminating risk of additive leaching into fluids) Adhesives or metal intermediates

Key innovations include:

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Service Advantages

Service Advantages Description
Material Versatility From brittle sapphire (ideal for chemical-resistant microfluidic chips) to flexible polymers (for disposable fluidic devices), our processes adapt to diverse substrates optimized for fluid contact.
Rapid Prototyping Functional prototypes delivered in short timeframes, accelerating design validation—including testing of microchannel flow, reagent compatibility, and seal integrity for fluidic applications.
Scalable Precision Consistent quality across small-batch and large-volume productions—ensuring uniform performance, such as reliable fluid flow rates across all microfluidic devices.
Cost Efficiency Wafer-level processing reduces per-unit costs significantly vs. chip-level bonding, making high-volume production of disposable microfluidic chips economically viable.

Service Process

A professional engineer will contact you to confirm your actual requirements, conduct a feasibility assessment, test material compatibility, and verify your performance objectives.

First, conduct small-batch experiments to verify whether the bonding strength and process parameters can produce the products you desire, ensuring the parameters are accurate.

We will produce customized samples tailored to your needs, in the quantity you require. A comprehensive quality inspection report will be provided before the products are delivered to you.

We operate automated production lines with real-time quality monitoring. This enables efficient production while minimizing batch-to-batch variations that may arise from manual manufacturing, thereby enhancing product quality.

Our service doesn't end when you receive the products. We will continuously track the product usage and regularly optimize the application process accordingly.

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Industry Applications

Semiconductors

3D chip stacking via wafer-to-wafer bonding, boosting density for AI processors—including integration with microfluidic cooling channels to manage heat in high-performance chips.

Biomedical

Implantable devices with RF-transparent glass seals, enabling wireless data transfer—along with microfluidic drug delivery systems and lab-on-a-chip platforms for rapid, low-volume sample analysis.

Aerospace

Hermetic packages for MEMS sensors, stable in extreme temperatures/vacuum—including microfluidic sensors for in-flight fluid analysis or fuel monitoring.

Optoelectronics

Micro-optics assemblies for 3D scanning, ensuring low-loss signal transmission—paired with microfluidic channels for precise sample positioning in optical diagnostic tools.

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Client Testimonials

"Creative Biolabs helped us solve a recurring PDMS-to-glass delamination issue that had stalled our project for months. Their engineering support was timely, clear, and highly professional."

— R&D Director, Industrial Sensor Firm

"Turnaround time was fast and the quality control reports were thorough. Every bonded device passed pressure testing with consistent performance."

— Engineering Lead, Semiconductor Manufacturer

"What impressed us most was the optical clarity after bonding. The channels remained crisp under high-magnification imaging, which is crucial for our single-cell assays."

— Product Manager, Medical Tech Company

"Their hybrid material bonding solved our GaAs-SiC integration issue for optoelectronic modules. Communication was clear, and the final bonds met our durability needs. Reliable partner for microscale challenges."

— Emma Carter, Optoelectronics Engineering Manager

"We needed hermetic seals for tiny MEMS sensors, and their laser bonding delivered consistent, leak-free results. Post-delivery support helped optimize our production flow too. Very satisfied."

— Mark Torres, MEMS Device Development Lead

"Ultra-thin wafer handling was critical for our semiconductor project. Their team adjusted processes to fit our substrates, and prototypes arrived on time with accurate bonding. Great technical expertise."

— Lisa Wong, Semiconductor R&D Specialist

"Wafer-level packaging reduced our per-unit costs significantly. The yield was steady, and their quality checks caught minor issues early. A valuable partner for scaling our microcomponent production."

— Ryan Patel, Microengineering Production Manager

Published Data

Plasma-activated high-strength non-isothermal anodic bonding for efficient fabrication of the micro atomic vapor cells

In one study, a non-isothermal anodic bonding process based on plasma activation was developed to achieve high-strength bonding at low temperatures using the temperature gradient to keep the alkali metal away from the bonding interface. This procedure eliminates interference from the alkali metal and significantly increases the success rate of anodic bonding of vapor cells.

Current and transferred charge curves during the different anode bonding processes. (OA Literature) Fig.1 The bonding current and charge transferred during anodic bonding.1,3

An alternative micro-milling fabrication process for rapid and low-cost microfluidics

The conventional method for bonding PMMA to PMMA is using acetone and pressure to create a permanent seal. This successfully bonded the acrylic together, but once smaller microchannels are used, they often collapse during the bonding process, leaving the channel closed off, and rendering the microfluidic chip unusable. This prompted research into different kinds of solvents. In one study, they used a substrate soaked in ethanol and baked in the oven for 30 min, however, it still damaged microchannels. In another study, this method was modified and the solvent was only applied to the pocket; the chip was then enclosed, sandwiched between aluminium plates, and baked at 90 degrees Celsius for up to 12.5 min. This resulted in a bond strong enough to seal without damaging the microfluidic chip.

How solvent bonding is conducted with the equipment in the image. (OA Literature) Fig.2 Solvent bonding.2,3

References

  1. Mingzhi Yu, Yao Chen, Yanbin Wang, Yintao Ma, Guoxi Luo, Shun Lu, Libo Zhao, Ping Yang, Qijing Lin, Zhuangde Jiang, et al. "Plasma-activated high-strength non-isothermal anodic bonding for efficient fabrication of the micro atomic vapor cells." Journal of Materials Research and Technology Volume 27,2023,2238-7854 https://doi.org/10.1016/j.jmrt.2023.10.029
  2. Allen, M.C.; Lookmire, S.; Avci, E. et al. "An Alternative Micro-Milling Fabrication Process for Rapid and Low-Cost Microfluidics." Micromachines 2024, 15, 905. https://doi.org/10.3390/mi15070905
  3. Distributed under Open Access license CC BY 4.0, without modification.

Created November 2025

FAQs

Q: What materials can you bond for microfluidic chip fabrication?

A: We support PDMS, glass, COC, COP, PMMA, PC, and hybrid combinations. Our team evaluates your design and application requirements to recommend the most reliable bonding method.

Q: How do you ensure channels remain clean and unobstructed after bonding?

A: We use controlled surface activation, particle-free workflows, and pre-bond inspection to prevent contamination. Every device undergoes post-bond optical checks to confirm channel integrity.

Q: Can your bonding process withstand high-pressure or high-temperature operations?

A: Yes. We offer thermal fusion, plasma bonding, and solvent-free approaches that deliver strong seals suitable for elevated pressures or temperature-dependent assays.

Q: How do you minimize bubble formation during or after bonding?

A: We optimize surface energy, pre-conditioning steps, and bonding pressure profiles to promote uniform sealing and reduce trapped air. QC testing ensures bubble-free channels.

Q: Do you provide bonding for custom chip geometries or multilayer structures?

A: Absolutely. We routinely handle non-standard layouts, multi-layer stacking, and complex channel networks. Our engineers will review your CAD files and propose suitable bonding strategies.

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Precision bonding is the invisible foundation of breakthrough microdevices. Our team brings expertise, flexibility, and innovation to every project. Contact our engineers today for a customized consultation—let's turn your microscale vision into reality.

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