This study demonstrates the application of High Power Ultrasonic Microembossing Technology (HPUMT) in producing microfeatures on polymer substrates. The work reviews a novel method of obtaining flash free and precise microfeatures by manipulating the material density through microcellular foaming. The microfeatures created on the polymer substrates were further characterized by analyzing the feature depth with respect to the critical ultrasonic embossing operating parameters such as embossing heating times (s), embossing amplitude (ym) at a constant embossing trigger force (N). An experiment design was constructed and performed to characterize the parameters on foamed and unfoamed (or regular) versions of polystyrene (PS) and polypropylene (PP) sample materials. Results indicated feature depth was proportional to heating times, amplitude and force. It was also seen the maximum depth was achieved in the shortest cycle times with higher amplitudes and forces of operation.

HPUMT was further studied to create functional network of microchannels functioned as reservoirs, reaction chamber and burst or gate valves to form a centrifugal biosensing platform that is also referred to as a lab-on-CD or a bio-CD device. The surface energy of the polymer substrates was increased to enable fluid flow by using a surfactant based organic coating to facilitate hydrophilicity. Using an organic light emitting diode (OLEDs) as an electroluminescence source provided luminescence decay results in good agreement with stern-volmer relationship. The functionality of the OLED-coupled lab-on-CD device was further tested in measuring unknown concentrations of a particular analyte in corn slurry sample which contained numerous contaminants. Combinatorial multianalyte sensing was also made possible on a single bio-CD using a four photodetector (PD) quad preamp disk sensor.