Micro Injection molding combined with the use of removable inserts is one of the most promising manufacturing process for microfluidic devices, such as Lab-on-a-chip, that have the potential to revolutionize the healthcare and diagnosis system. In this work we have designed, fabricated and tested a compact and disposable plastic optical stretcher. To produce the mould inserts, two micro manufacturing technologies have been used. Micro Electro Discharge machining was used to reproduce the inverse of the capillary tube connection characterized by high aspect ratio. Thanks to the high accuracy of femtosecond laser machining, instead, we manufactured insert with perfectly aligned microfluidic channels and fiber slots, facilitating the final composition of the optical manipulation device. The optical stretcher operation is tested using microbeads and red blood cells solutions. The prototype presented in this work demonstrates the feasibility of this approach that should guarantee a real mass production of ready-to-use- Lab-on-a-chip.
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