Methods for compression molding through holes in polymer layers are
provided, as are the resulting patterned polymer layers. Two key aspects
of the invention are provision of a mold and substrate having different
mechanical hardness, and provision of room for local flow of material.
These aspects of the invention facilitate formation of through holes by
compression molding that are not blocked or partially blocked by
undesirable material. These polymer layers can be formed into three
dimensional patterned structures by bonding patterned layers together.
Since the layers include through holes, a three-dimensional polymer
pattern can be formed. These patterned polymer layers and three
dimensionally patterned polymer constructs have a wide variety of
applications. For example, these constructs can be used for fabrication
of micro-fluidic devices, and/or can be used for various medical and
biological applications including drug delivery devices and tissue
engineering devices.