A microfluidic chip is only as good as its design margins. These rules keep glass chips manufacturable and reliable.
Channel geometry
Keep aspect ratios within process limits and avoid sharp internal corners that concentrate stress.
Minimum wall thickness
Leave enough glass between adjacent channels to survive bonding and handling.
Ports and interconnects
Space ports to match your world-to-chip interface and allow for drilling tolerances.
Bonding allowances
Plan for the flatness and cleanliness that thermal fusion bonding requires; small particles become large defects.