We study a combinatorial problem arising from microarrays synthesis. The synthesis is done by a light-directed chemical process. The objective is to minimize unintended illumination that may contaminate the quality of experiments. Unintended illumination is measured by a notion called border length and the problem is called Border Minimization Problem (BMP). The objective of the BMP is to place a set of probe sequences in the array and find an embedding (deposition of nucleotides/residues to the array cells) such that the sum of border length is minimized. A variant of the problem, called P-BMP, is that the placement is given and the concern is simply to find the embedding.Approximation algorithms have been proposed for the problem [22] but it is unknown whether the problem is NP-hard or not. In this paper, we give a thorough study of different variations of BMP by giving NP-hardness proofs and improved approximation algorithms. We show that P-BMP, 1D-BMP, and BMP are all NP-hard. Contrast with the result in [22] that 1D-P-BMP is polynomial time solvable, the interesting implications include (i) the array dimension (1D or 2D) differentiates the complexity of P-BMP; (ii) for 1D array, whether placement is given differentiates the complexity of BMP; (iii) BMP is NP-hard regardless of the dimension of the array. Another contribution of the paper is improving the approximation for BMP from O(n 1/2 log 2 n) to O(n 1/4 log 2 n), where n is the total number of sequences.