Patent ID: 8865091

Claim:
A method of manufacturing a sample processing device, the method comprising: providing a multi-layer polymer melt stream having two separate and discrete layers, the layers comprising: a transmissive layer that transmits selected light; and a control layer that blocks the selected lights; wherein the control layer comprises a polymeric material at or above a melt processing temperature of the polymeric material; wherein the control layer is attached to the transmissive layer with a first major surface of the transmissive layer facing the control layer and a second major surface facing away from the control layer; and while the control layer is held at or above the melt processing temperature, forming a plurality of process chamber structures in the control layer such that each of the process chamber structures comprises an interior window surface proximate the first major surface and an interior side surface formed by the control layer, wherein the interior window surface within each process chamber structure is formed by a thinned portion of the control layer, and wherein the thinned portion of the control layer is sufficiently thin so that the thinned portion of the control layer transmits the selected light.