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Scalable wafer level production of consumables made of
non-CMOS compatible materials on glass
Dr. Alexios-Paul Tzannis
• Challenges in the field of microfluidics
• A diversified market
• Lack of Standardisation
• Opportunities utilizing the foundry concept
• IMT’s solution
• Conclusions and outlook
Outline
• Each application is based on a different detection
scheme, i.e. biosensor technology
• Though same application, due to patent restrictions
different road paths
• no standardisation
• Understanding the needs translate these into
deliverables
• Immense time pressure
• Multiple iterations
• rapid prototypes
• ability to scale-up
• Cost efficiency
Challenges for a foundry
What is a biosensor??
A biosensor is an analytical device, used for the detection of an analyte, that
combines a biological component with a physicochemical detector.
Signal Transduction Mechanisms
Diverse road maps
No standardisation
Source: Corning Life Sciences 2012 at ALSSA
Fall Senior Management Conference.
The Life Science Tools
market is very diverse in
terms of technologies;
molecular and cellular
biology tools and reagents
account for 36%
A diversified market
Advances in technology promote decentralization
Source: Scientia Analysis, Roche
Medical equipment are decreasing in size and becoming easier to use
SEMI-PORTABLE EQUIPMENT
TRADITIONAL EQUIPMENT
Large, stationary equipment that
must be operated by healthcare professionals
MOBILE EQUIPMENT
Bench-top and handheld devices
used in clinics and POs allowing for faster, on-site
results
Small devices for clinical and in-
home use requiring little to no professional
assistance
FUTURE
Ref: ©2015 | www.yole.fr | Microfluidic Applications 2015
Material of choice vs. Application
Classical questions to be addressed
• I want to utilise fluorescence detection
• transparency at the UV or visible range
• Single molecule detection low signal
• I want to utilise an electrochemical transducer • Integrate electrodes in the chip
• They have to be of Au
• I need to modulate my signal in the KHz
• I want many measuring points per mm2
• Bio functionalisation, e.g. covalent bond chemistry
• Localised bio functionalisation
• periodic sub-micron bio functionalisation
• I want mass manufacturing and low cost
• I need integration of filters, pumps, wet chemistry on the cartridge
• It needs to be dummy safe
Initial idea prototyping Serial
production
Feasibility Iteration &
Ramp-up strategy
Scalability
Standardisation
QC
IMT’s value chain for MF consumables supply
How do we address the diverse requirements of the life science community?
• Implement full MEMS compatible processes
• Address the challenges by utilising non-CMOS compatible materials
• Target hybridisation to use the best of each material and technology
Automated process line for 200mm wafers
Glass cleaning Coating Resist Coating Exposure Wet Process
Dicing Final Cleaning Bonding AOI
Flexible Capacity > 14 - 20’000 wafers/month
from 1 to 1Mio. glass chips per month
RIE-cluster
Metallic and reactive sputtering
Automated loading and coating of
batches of 16 x 200mm wafers
Masking for HF-etched patterns in glass
Isotropy / Anisotropy is controlled
by selecting:
• The right mask material (chrome)
• The right tool and method (sputtering)
by tight control of:
• The masking material and its properties
• The glass material (polished, drawn, ..
320m
150m
Isotropically HF- etched structures Anisotropically etched HF- etched structures
HF Spray – etching chamber
High-volume controlled etching of lithographically defined
microstructures in glass
16 x Ø200mm Wafer / batch with excellent homogeneity (± 1% within the batch)
Complete processing dry-in – dry-out (Resist development,
chrome & glass etching resist/chrome strip)
Use of different
- chemistries and concentration (HF, HNO3, HCl,…) and
- glass types (B270, D263, Borofloat, Mempax, fused Silica,
Float….)
Development and large scale manufacture of
cost effective glass consumables
• Complete assembled flow cells
• Nano- and micro-patterns on glass
• Nano-wells and channels in glass
• Nano-pillars in glass
• Structured electrodes on glass
• Planar or structured Waveguides and phase gratings to guide and couple light
• Covalent bond chemistry
• Structured polymers (photoresists)
• Through-holes
• (Adhesive-) Bonding of glass substrates
• in-house master manufacture
• All processes in-house
Service offering to the Bio Photonics industry
• Structured polymers (SU-8, CBC, TMMF, Ordyl, CYTOP ...)
• Polymer as intermediary layer for micro fluidic solutions
• High degree of freedom in pattern design
• Combination with electrodes, waveguides, nano-wells and other patterns
possible, e.g. bio functionalisation
Chip functionalisation: intermediary layer
Ti-Au electrodes in a channel generated by
patterning SU-8. SU-8 pattern 350µm deep
Ti-Au electrodes integrated within a
microfluidic channel
Wafer Bonding by UV-adhesive transfer process
Adhesive Bonding
Bonding with adhesives can be used to
join many different materials, e.g.
Glass, Silicon, polymers . Often liquid
adhesives are used, which can be
cured thermally or by exposure to UV-A
light, offering a room-temperature
bonding process, which allows for bio-
molecule encapsulation.
Key features
• Ultra-thin selective adhesive transfer
technology with excellent uniformity
over large areas
• Room-temperature processes for
encapsulation of bio-materials
• Compatible with a wide range of
materials, e.g. CTE
• Insensitive to surface roughness
D263
D263/Silicon/Polymer
UV-cement
Hybridisation of materials
D263
D263
Hybrid materials (Glass-Si, Polymer-Si, Glass-Polymer…) are being increasingly
used, since they enable the integration of additional functionalities to the chips
(e.g. sensing functions: electrodes, measurement points, temperature probes,
optical sensors…).
This trend aims to answer the increasing demand for functional integration in
microfluidic devices.
Ta2O5 & grating / nano-wells / electrodes / structured covalent bonds
S.C. Bürgel et al. / Sensors and Actuators B 210 (2015) 82–90
Hybridisation of Materials / Technologies
Hybrid solution proposed by IMEC / BE, http://www2.imec.be/be_en/home.html
VirCelChip NMI Reutlingen / MFCS / IMT AG
IMT AG
Hybridisation of Materials / Technologies
IMT AG Veredus Laboratories / STMicroelectronics Pacific Biosystems
Pick&Place equipment
Conclusions
IMT AG provides leading edge BioMEMS technology transferring the
microfabrication know-how originally developed for microelectronics into
flexible and scalable solutions for the manufacturing of micro- and
nanostructures on/in glass for consumables in life science applications and
components in medical instruments and equipment. CMOS processes for non-CMOS materials:
• free choice of glass substrate or other
• Electrodes of Gold, ITO, Platinum
• Adhesives and polymers
• Silanes, …
Opportunities for the customer:
• Hybrid solutions
• wide process portfolio for biosensor consumables
• From one-off prototypes to large scale manufacturing
• Full QC, complete traceability
• Effective turn-around times and optimal costs scenarios
IMT your solution provider
Thank you for
your attention!
Dr. Alexios Paul Tzannis
Business Development Manager
+41 44943 1966