Method for Etching Microchannel Networks within Liquid Crystal Polymer Substrates

A method of forming a patterned microchannel network in a liquid crystal polymer substrate, the method comprising the steps of:

• applying a copper layer to a liquid crystal polymer layer to form a copper clad liquid crystal polymer substrate;
• applying a patterned photoresist to the copper clad liquid crystal polymer substrate, the patterned photoresist defining a desired microchannel network;
• exposing the patterned photoresist to a light source;
• developing the exposed patterned photoresist;
• etching the copper layer of the copper clad liquid crystal polymer substrate, defined by the patterned photoresist, to expose the liquid crystal polymer layer of the substrate;
• removing the patterned photoresist from the substrate;
• and
• etching the exposed liquid crystal polymer layer of the substrate to a predetermined depth, thereby forming a patterned microchannel network in the substrate.