Diffusion Bonding of Polymer Based Devices

Webinars 28 May 2025

When:

28 May 2025

10:00 - 11:00 BST

Venue:

Online

Webinars 28 May 2025

TWI Core Research Programme Showcase - Diffusion Bonding of Polymer Based Micro- and Nano-fluidic Devices

Micro-channelled polymer components are increasingly employed in applications such as heat exchangers, microreactors, and diagnostic lab-on-a-chip devices. Ensuring robust, reliable joints within these intricate channel architectures is critical to maintaining their performance and structural integrity. TWI has been investigating diffusion bonding as an innovative, non-adhesive joining method for these polymer systems. By carefully controlling variables such as temperature, pressure, and bonding duration, it is possible to achieve strong, uniform joints while preserving the delicate micro-channel geometry.

This presentation introduces the principles of diffusion bonding in polymers, describing the key process parameters and equipment considerations, as well as the mechanical and microstructural assessments used to validate bond quality. Attendees will see how diffusion bonding can maintain channel fidelity while delivering excellent bond strength, to offer a reliable, scalable solution for fabricating advanced polymer-based devices for a range of applications, from thermal management to medical diagnostics.

Meet the team

Dr Abbasi Gandhi

Principal Project Leader, Thermal Processing Technologies (TPT) Section at TWI

Abbasi is material scientist (PhD) with engineering background (BEng and MEng) and 15 years of R&D experience in highly regulated industries, such as medical device, automotive, pharmaceutical, aerospace, novel testing instruments, data storage, power generation and materials safety. As well as having written 35 peer-reviewed journal papers, 3 granted patents and 3 book chapters, Abbasi has presented his work in 53 national/international conferences. He is a reviewer for material science related international journals.

Abbasi is leading projects investigating EV battery joining processes, diffusion bonding, powder sintering, micro joining, low thermal mass heater devices, electroless plating, wire bonding, brazing of biomedical implants and developing electrical/mechanical testing capabilities for EV battery joints at TWI.

Ian Froment

Section Manager - Membership Development

Ian Froment is TWI's Section Manager for the Membership Development Section. as well as Industrial Membership Manager for the Power Generation and Medical Sectors.

Ian is responsible for interfacing with TWI Industrial Members in the nuclear, fossil and renewable energy sectors. Ian Froment can support direct technical enquiries as well as answer questions on TWI's membership services, ultimately maximising value for TWI.

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