High-throughput fabrication of biofunctional polymer surfaces via ultrafast laser structuring and injection molding

Imaging dishes and chambers are essential tools in microscopy, especially for live-cell studies. They are widely used due to their easy and cost-efficient production via injection molding and the advantageous properties of polymers, such as biocompatibility and optical transparency. A major challenge in cell research is single-cell analysis, which provides a more precise understanding of cellular mechanisms and population heterogeneity. This process involves distributing cells in spatially separated microcavities. Our study presents an efficient, large-scale approach to fabricating functionalized imaging dishes by combining ultra-short pulse laser processing with injection molding. We fabricated honeycomb-like cavities (100 µm in diameter) and microgrids (10 µm in line width and less than 1 µm in depth) on cyclic olefin polymer (COP) surfaces. This method enables the replication of existing structures and the integration of microgrids for the spatial control of cell populations. The combined process significantly reduces manufacturing time and cost while adding new functional capabilities.