Fluid Circuit and Manifold Design using an Integrative Polymer Laminate Platform

www.alineinc.com

About Us

• Founded in 2003

• Micro fabrication for any product concept requiring devices/features in the mm dimension or smaller

• Concept to Scalable Working Prototype

• Production up to 1MM/yr

• Medical Design Excellence Award – 2009 Honored as Supplier to Gold Winner in IVD

• Supported 2 R&D 100 Award winning programs - 2011 & 2012

• LA Business Journal & PSS Innovation Award Finalist 2012

Awards and Honors

• Engineering staff with 40+ years experience in microfluidics

• Provide practical, real world solutions

• Proven functional elements

• Integrate functions with minimal complexity

• r&D to commercialization

Our Expertise

Integrative Polymeric Platform

Easy to:

• Prototype and test new designs/materials.

• Measure effect of stack tolerances on performance.

• Incorporate a variety of materials.

• Assemble to other components.

• Scale for volume production.

Advantages of IPP

MATERIALS SUBSTRATE Thickness (English) Thickness (Metric)

Max. Min. Max. Min.

PMMA 0.080" 0.002" 2 mm m

PET 0.060" .0005" 1.5 mm 12.5 m

POLYCARBONATE .010" .005" m 125 m

POLYSTYRENE .005" .002" 125 m 50 m

POLYPROPYLENE .040" .002" 1 mm 50 m

COP/COC .007" .002" 175 m 50 m

SILICONE .060" .005" 1.5 mm 125 m

POLYIMIDE .003" .001" m m

FEP, PTFE, PVDF .010" .001" 250 m 25 m

BONDING

SILICONE .003" .001" m m

ACRYLIC .010" .001" m m

THERMAL BOND (160°F) .003" .001" m m

Integrated Components

Filling pump.

Discharging pump.

On–Board Diaphragm Pump

http://www.alineinc.com/pdf/On_board_pneumatic_valves_ALine_Inc..pdf

http://www.alineinc.com/pdf/Modular_Designs_for_Reproducible_Performance_of_On-Board_Pumps.pdf

Diaphragm valve open

Diaphragm valve closed

On–Board Diaphragm Valve

• External control of fluid actuation

– Performance more tolerant to variation in material properties.

– Instrumentation with sensors for calibration and control.

• Shift complexity to the instrument, reduced cost of the disposable.

Electro-Mechanical Control

Design Rules

Feature Min. Max. % Var

Channel Width 125 m 1.5 mm 10 to 5%

Channel Height 25 m 2 mm 5%

Vias 100 m -

Feature Density 1 mm -

Valve Width 2 x 3mm -

Pump Diameter 2 mm 10 mm

Porous Membrane 3mm2

100 cm2

Overall Dimensions 7 mm2900 cm2

Stack Tolerance 75 m 125 m

On-Chip Functions

FunctionComponent

RequirementsControl

Electromechanical

Requirement

Actuation

States

Fluid Line Toggles Diaphragm Valve activethree-way valve; +7, -7,

atm psi

close, +7;

open, -7;

rest, atm

MeteringDiaphragm Valve,

Vent, Channelactive

three-way valve; +7, -7,

atm psi

fill, -7;

dispense, +7;

rest, atm

DispensingVent and/or

Diaphragm Pumpactive

3 three-way valves; +7,

-7, atm psi

close, +7;

open, -7;

rest, atm

Mixing Diaphragm Pump

and Vent active

3 three-way valves; +7, -

7, atm psi

close, +7;

open, -7;

rest, atm

Air Bubble Control Venting Channelsactive/

passive

two-way valve; -7, atm

psi-7 psi; atm

ALine Tool Box of Microfluidic Components

Modular Designs Well established fabrication and assembly processes minimize variability

PSA or UV Cure

PSA or Thermal

Bond

Injection molded sample port reservoirs, blister packs, waste

4 to 7-layer laminate; valves, pumps membranes, vents, channels

Optical or Electro-active Sensor and additional channel layer (if needed)

S1

S2

S3

ADEPT Developer’s Platform Applications

Control and Monitor Fluid Movement

Controlled Interface to Pneumatics

Actuation Routine Development

Quality Control

Configurable

4 to 32 valves, 2 pumps.

Multiple Pressure Sensors

Manual toggle or computer control with interface to LabView.

Micro SD card and text-based programs.

Visualization and Recording

Optically clear x-y custom manifold,

Camera or Optical Comparator

Manufacturing Methods

Mass or Flow Manufacturing Batch or Flexible manufacturing

Method Flow of material is linear through the process, equipment fixed, and produces one product

Material moves through each type of operation in a group,

equipment is adaptable to different products

Flexibility None - every piece of equipment linked together for production of a single product

Some - equipment is modular and mobile to maximize work

flow efficiency

Capital Investment

High Capital Investment + High NRE

Low Capital Investment + Low NRE

>1 MM/yr <1 MM/yr

$ $$$$

$$ $$

1MM parts/yr = 1 part every six seconds (85k parts/month)

• Laser Cut and Lamination

– Fluid Circuits with Integrated

Valves , Pumps

• Robotic Pick and Place

– Porous membranes, pop-on

components

• UV Dispense and Cure

– Assembly to injection molded

parts

Automation

Commercialization

Roadmap for Scale-up of a Proof of Concept Design

Volume 1,000 10,000 100,000 1,000,000

Process Manual PLT Automated PLT Fully Automated PLT + Optimized Design

Roll to Roll+ Optimized Design

Device: 7 layer design with

mixed materials, on-board valves,

vents, Pop on Subassemblies

pin fixtures, manual

cleaning and assembly

Gantry laser, automated lamination,

current design

Further improvements in

channel formation method, and processing

Dedicated mfg. line, reduced

material costs, simplified design

Per Piece Price (Estimate)

$22.00 $12.00 $5.00 $1.50

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Summary The IPP approach permits rapid prototyping of fluid circuit and manifold designs in less than one week.

Our engineering staff supports problem solving for tough designs

Easy to incorporate mixed materials

Alternative to dye-cut parts for initial testing

Provide reliable, high quality parts with scale for volume production.