Digital PCR Filter Tube & Automated Manufacturing System
Sector
Laboratory Equipment, Automation Systems
Background
A medical device manufacturer needed a disposable DNA sample filtration system for their new PCR product. The problem? Nothing on the market came close to meeting their specifications. We developed the filtration solution from scratch, engineered the manufacturing process, and then designed the automated production systems to manufacture it in-house at scale.
Challenge
Micro-tissue particulates were clogging their PCR instrumentation, rendering tests useless. Standard filtration solutions couldn't integrate with their system's precise tubing geometry. The filter needed to catch particles at the micron level while maintaining perfectly smooth internal surfaces. Any imperfection would trap DNA samples and contaminate subsequent tests. After developing the filter tube and proving the manual forming process, the real challenge emerged: automating production to achieve repeatable micron-level precision at commercial manufacturing speeds.
Solution
We engineered a two-stage thermal forming process that transforms standard tubing into precision filtration components through controlled compression and stretching. Beyond the process itself, we designed and manufactured complete automated production systems integrating thermal control, precision mandrel positioning, real-time process monitoring, and operator feedback systems. The automated units deliver single-button operation with consistent micron-level accuracy, giving the client full manufacturing capability to produce their proprietary filtration system at the volume and quality their product demanded.
