This paper describes the results of fabricating plastic microfluidic devices and creating a microvalve array for protein separation. Plastic devices are selected due to low cost of raw materials, bio-compatibility, and disposability. Although the methods for fabricating plastic devices have appeared in literature, reports typically indicate one set of conditions that yield functional devices. We report a systematic study of fabrication process parameters including compression rate, molding temperature, and the compression force used by a hydraulic press. Their effects on the device thickness, channel dimension, and pattern transfer fidelity will be discussed. In addition, we investigated creating an array of pseudo-microvalves using photodefinable, in situ gel polymerization. The valves were developed for introducing two types of separation media for performing two-dimensional protein separation in a microfluidic device. We also demonstrated rapid protein separation using the mechanism for the first dimension, isoelectric focusing.

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