Case Studies: Microfluidic, Optical & Flow Cell Projects

Five-layer bonded PMMA microfluidic chip

Microfluidics · IVD

5-layer PMMA chip holds ±8 µm channel depth at series scale

Challenge. A point-of-care developer had a working prototype machined in-house, but channel depth drifted between lots and thermal bonding occasionally collapsed the shallower channels.

What we changed. We switched to stress-relieved cast PMMA, adjusted the bonding profile to a two-stage ramp with controlled pressure, and added in-process depth measurement on 100 % of wafers before bonding.

Result. Depth held to ±8 µm over a 75 × 25 mm footprint, burst pressure above 4 bar, and a first production lot shipped in 21 days.

±8 µmChannel depth

4 barBurst pressure

21 daysFirst lot

$Diamond fly-cut acrylic light guide$ Optics · Diagnostics

Acrylic light guide replaces glass at one third of the cost

Challenge. A reader manufacturer was using a ground glass light guide. Cost and a fragile supply chain pushed them to look for a polymer alternative, but early acrylic attempts lost 15 % transmission at the coupling face.

What we changed. Diamond fly-cutting of both end faces to Ra 0.02 µm, edge blackening to control stray light, and a fixture that keeps the part flat during polishing.

Result. 92 % transmission across the working band, part cost reduced by 65 %, no change to the optical model in their firmware.

Ra 0.02 µmSurface finish

92 %Transmission

−65 %Part cost

Bonded acrylic flow cell with quartz windows

Water · Analytical

In-line flow cell survives 10,000 pressure cycles

Challenge. A turbidity sensor maker was losing units in the field to window debonding. The acrylic body bonded to quartz windows failed at the adhesive interface under thermal cycling.

What we changed. Moved to a two-component adhesive with matched CTE, added a mechanical register so the bond line carries no shear, and introduced 100 % pressure-decay testing.

Result. Zero leak failures across 10,000 accelerated cycles at 6 bar; field return rate dropped from 3.1 % to under 0.2 %.

10 kPressure cycles

0Leak failures

<0.2 %Field returns

Multi-port acrylic manifold under inspection

Valves · Manifolds

24-port manifold machined to ±15 µm true position

Challenge. A fluidics integrator needed 24 ports on a single acrylic block, aligned well enough for push-to-connect fittings to seal without thread sealant.

What we changed. Single-setup machining on a granite-bed mill with a custom fixture, drilling sequenced to avoid thermal drift, and CMM verification of every port position on the CMM before assembly.

Result. True position within ±15 µm across the face, assembly leak test pass rate 99.6 %, and a repeatable 12-day cycle for series orders.

±15 µmTrue position

99.6 %Leak test pass

12 daysSeries cycle

Problems we were actually asked to solve

Twenty H7 bores at Ø0.02 mm true position — on a painted, engraved acrylic plate

5-layer PMMA chip holds ±8 µm channel depth at series scale

Acrylic light guide replaces glass at one third of the cost

In-line flow cell survives 10,000 pressure cycles

24-port manifold machined to ±15 µm true position

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