PCBMEMS have previously been incorporated within rigid substrates. Flexible laminates are also possible to incorporate PCBMEMS, called Flex PCBMEMS, and at times are desirable for maximum packing density and miniaturization. In this work demonstrations using 2D to 3D packaging transforms on a compact heated fluorometer block are presented. In one case the optoelectronic reference block is further integrated using flexible PCB/MEMS. The block is transformed with the insertion of a polyimide flex opto/mechanical/electrical interconnect skin. In a second example the block is further miniaturized into a mini tube using planar fabrication and flexible folding of the fluorometer system. This design, fabrication and construction approach allows lightweight, complex, space efficient systems. Flex PCBMEMS permits miniaturization to occur at two levels: at the micro scale with the embedding of microstructures in the substrate, and at the macro scale with the ability to flex the system across millimeter to centimeter lengths of real everyday objects. Using this path Flex PCBMEMS can approach the creativity and complexity of natural systems.

A compact hand-held heated fluorometric instrument for performing real-time isothermal nucleic acid amplification and detection is described. The optoelectronic instrument combines a Printed Circuit Board/Micro Electro Mechanical Systems (PCB/MEMS) reaction detection/chamber containing an integrated resistive heater with attached miniature LED light source and photo-detector and a disposable glass waveguide capillary to enable a mini-fluorometer. The fluorometer is fabricated and assembled in planar geometry, rolled into a tubular format and packaged with custom control electronics to form the hand-held reactor. Positive or negative results for each reaction are displayed to the user using an LED interface. Reaction data is stored in FLASH memory for retrieval via an in-built USB connection. Operating on one disposable 3 V lithium battery >12, 60 min reactions can be performed. Maximum dimensions of the system are 150 mm (h) × 48 mm (d) × 40 mm (w), the total instrument weight (with battery) is 140 g. The system produces comparable results to laboratory instrumentation when performing a real-time nucleic acid sequence-based amplification (NASBA) reaction, and also displayed comparable precision, accuracy and resolution to laboratory-based real-time nucleic acid amplification instrumentation. A good linear response (R2 = 0.948) to fluorescein gradients ranging from 0.5 to 10 μM was also obtained from the instrument indicating that it may be utilized for other fluorometric assays. This instrument enables an inexpensive, compact approach to in-field genetic screening, providing results comparable to laboratory equipment with rapid user feedback as to the status of the reaction.

Within the traditional mass spec instrumentation field there is ongoing interest in new atmospheric ion source designs for more effective and versatile ion generation. The objective of the present study is to apply organic MEMS microfabrication technologies to generation of atmospheric pressure ion optical devices. We have devised novel materials, processes, and designs for micro ion optical systems for control of ions within sources, and across apertures and conductance arrays. PCBMEMS using LCP have been used in the construction of the devices. Vacuum compatibility of the polymeric material has been found to be similar to glass in performance characteristics. Processes for shaping the polymer dielectric for fluid flow control and the metallization for electrical field control have been devised. Different geometries, both tubular and planar, combined with electrical field shaping circuitry and fluidic flow control networks are part of the effort.

We are developing integrated microsystems and sensor networks for in-water measurements using PCB MEMS, also known as organic MEMS. The PCB MEMS laminates are based on liquid crystal polymers (LCP), polyimide (PI) and FR-4 materials with the various sensing elements made within or on top of the printed circuit substrates. Single layer, double layer, and laminate constructions have been achieved. The sensing systems that utilize this technology are directed toward chemical, biological and physical sensing devices. Recent progress in sensor development has yielded PCB MEMS sensors operating in the field. We have developed a multisensor system that measures conductivity, temperature and pressure, and a compact 3D system-in-package wireless module based on the 802.11b protocol. Combining the sensor and telemetry modules yields wireless sensor systems capable of being scaled into networks. The microsystems made in this economical PCB MEMS format can be utilized in the marine environment, especially in emerging adaptive sensor grids, but also be applied to terrestrial, atmospheric and industrial process control environments.