Alejandro Abarca Blanco
Zen Fluidics (Lab On A Chip & Microfludics)
In collaboration with Zen Fluidics, I was approached to assemble a multidisciplinary team of engineers to develop a new product line of laboratory automation devices specialized in microfluidics.
Zen Fluidics offers modular devices (valves, sensors, sample holders, tubing, etc.) that can be interconnected to easily prototype microfluidics or "lab on a chip" experiments for medical or biotech facilities.
1. Application Examples
The devices from Zen Fluidics have been successfully employed in prototyping and developing applications in healthcare. For instance, the following provided outlines for an automated on-chip ELISA capable of detecting anti-SARS-CoV-2 antibodies in serum samples taken from COVID-19 patients and individuals who have been vaccinated.
2. Market Research & Prototyping
Our journey commenced with extensive market research and user consultations to comprehend the challenges and inefficiencies faced in manual microfluidic experimentation setups. With these insights, our team sketched initial design concepts, focusing on modularity, scalability, and automation. Leveraging advanced CAD tools, we digitally design prototypes to evaluate performance and identify potential bottlenecks. To bring our designs to life, rapid prototyping techniques like 3D printing, CNC machining, basic electronic prototypes, soft lithography with PDMS and SU-8, etc., were employed, ensuring quick feedback loops and iterative improvements. Concurrently, we worked closely with end-users, conducting hands-on sessions to evaluate ergonomics, user-interface, and automation efficiency.
3. Initial Design
Our extensive market research and initial prototyping revealed that microfluidics experimentation was full with challenges. These challenges often diverted scientific researchers and engineers from their primary objectives, causing them to lose time repeatedly "reinventing the wheel". They would use pumps and sensors that weren't always capable of handling the low volumes characteristic of microfluidic applications.
Additionally, many life science users sought user-friendly interfaces with minimal electronic or programming requirements. Therefore, we developed user-friendly fluid pumps, sensors, and valves to cater to their needs.
4. Zen Fluidics Pressure & Flow Controller
The heart of a microfluidics application is the pressure and flow controller, a device designed to precisely regulate and control the pressure and flow rate of fluids in microfluidic systems. Microfluidic systems deal with small volumes of fluid (typically in the microliter to picoliter range) within channels that have dimensions in the micrometer scale. Given the tiny volumes and channels, accurate control of fluid movement is crucial. This can be particularly important in applications like cell studies, chemical reactions, or when working with sensitive biological samples in the microfluidic device.
5. Additional Components
In addition to the primary controllers, our development extended to include a range of supplementary components aimed at streamlining and enhancing the microfluidic system design.
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Valves were introduced to provide on-demand control of fluid direction and flow, enabling users to stop, start, or redirect fluid as required.
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Rotary valves, a specialized variant, offer the ability to select from multiple channels or pathways in a single rotary switch mechanism, thus adding an extra layer of flexibility in routing the fluid.
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Flow sensors were incorporated to continuously monitor and measure the rate of fluid flow, ensuring precision and alerting users to any anomalies or deviations.
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Traditional tube interfaces, ensuring compatibility with pre-existing laboratory setups and equipment, were also added.
These components work in synergy, allowing for a modular, adaptable, and comprehensive microfluidic system that simplifies design while maintaining high functionality.
6. Software
Agile development methodologies were employed, fostering iterative development, continuous testing, and feedback loops. Recognizing the complexity of microfluidic processes, we emphasized the development of an intuitive user interface, ensuring ease of setup, real-time monitoring, and data analysis capabilities. Collaboration with the hardware team was continuous, ensuring seamless integration and synchronization between the software and the physical devices.
7. Design for Manufacturing, Quality and Component Availability
While developing our cutting-edge microfluidics product line for automated experimental setups, a multifaceted strategy was adopted to ensure Design for Manufacturability (DFM), reliable supplier partnerships, stock component availability, and stringent quality assurance. First, early in the design phase, we integrated DFM principles, ensuring our designs were both innovative and production-ready.
To streamline production and reduce lead times, we established partnerships with key suppliers, vetting them based on their track record, quality standards, and capacity to meet our demands. Regular audits and performance reviews ensured supplier reliability and adherence to agreed specifications.
Given the critical nature of our devices, we maintained a strategic inventory of stock components, ensuring no disruption in production and rapid response to market demands. Quality assurance was interwoven throughout our process. From raw material checks to rigorous testing of the final product, each step was geared towards ensuring that our microfluidics devices were not only effective but also consistent and reliable, reflecting our commitment to excellence in the field.
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8. Training Material
We placed a significant emphasis on equipping users with quality documentation and comprehensive video tutorials. Recognizing that a product's efficacy is often gauged by its user's ability to utilize it optimally, our first step was to create an internal team of technical writers and multimedia specialists.
Collaborating closely with our engineering and research teams, they meticulously documented every feature, function, and potential application of our devices. Each documentation draft underwent rigorous reviews, ensuring clarity, accuracy, and relevance.
Parallelly, we embarked on producing video tutorials, emphasizing a hands-on, visual approach. These tutorials, shot in high-definition with clear narrations, guided users step-by-step, from setup to advanced experimentation.