The development and growth of microfluidics has been mainly based on various novel
fabrication techniques for downsizing and integration of the micro/nano components. Especially, an
effective fabrication technique of three-dimensional structures still continues to be strongly required
in order to improve device performance, functionality, and device packing density because the
conventional lamination-based technique for integrating several two-dimensional components is
not enough to satisfy the requirement. Although three-dimensional printers have a high potential
for becoming an effective tool to fabricate a three-dimensional microstructure, a leak caused by
the roughness of a low-precision structure made by a 3D printer is a critical problem when the
microfluidic device is composed of several parts. To build a liquid-tight microchannel on such a
low-precision structure, we developed a novel assembly technique in which a paraffin polymer
was used as a mold for a microchannel of photo-curable silicone elastomer on a rough surface.
The shape and roughness of the molded microchannel was in good agreement with the master
pattern. Additionally, the seal performance of the microchannel was demonstrated by an experiment
of electrophoresis in the microchannel built on a substrate which has a huge roughness and a joint.
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