Abstract: The effects of surface tension and die swell on the shape of extrudate during micro profile extrusion were studied and compared both analytically and numerically. As the size of the extrudate reduces, the surface tension increased and affected the cross-sectional shape change significantly. Strategies were proposed to reduce the influence from surface tension and produce precision micro profiles.

Key words: microfabrication, micro extrusion, polymer, surface tension, die swell