Modelling modular microfluidic printing systems for high throughput assays
Xi worked with Arrayjet to build solid mechanics and CFD models of their modular microdroplet dispensing system, helping troubleshoot sealing issues, improve print performance and reduce development cost for advanced diagnostics platforms.
The Challenge
Arrayjet manufactures microfluidic droplet dispensing systems used to create high density microarrays for medical diagnostics and research. Their modular architecture allows a printhead to dock onto a JetSpyder aspiration device that draws samples from multi well plates. At the heart of this interface is a linear array of miniature gasket seals that must maintain tight sealing under varying pressures and repeated use. In practice, ensuring consistent sealing and fluid distribution is complex, and direct measurement inside the fluidic manifold is difficult. Arrayjet wanted deeper insight into seal behaviour and flow patterns to troubleshoot existing designs and inform future product development.
Our Approach
Xi developed coupled solid mechanics and CFD models of the gasket array and associated flow paths. Structural simulations were used to calculate contact pressures and deformation for gaskets with non standard geometry at different levels of compression. These models were then linked to CFD analyses that predicted pressures and flow rates within each seal pocket and throughout the manifold as fluids were aspirated and dispensed. By comparing simulation results with measured flow and printing performance, Xi helped identify where leakage, air ingress or uneven flow distribution were most likely to occur. The models provided a virtual test bed for evaluating new manifold geometries and gasket designs before committing to hardware.
The Results
We approached Xi to better understand the sealing forces & flow patterns within our microfluidic devices. Xi had the knowledge and resources to examine the system accurately and provide in-depth studies. This has been a hugely enlightening process which has allowed us to make well-informed design decisions without the time-consuming iterative testing process.”
Alasdair Burnett
mechanical design engineer, Arrayjet Ltd
Why it matters
Modern diagnostic and life science platforms depend on precise control of micro scale fluidics. This collaboration shows how Xi’s Multiphysics modelling can help equipment manufacturers understand complex sealing and flow behaviour, reduce trial and error and de risk product launches. The approach is transferable to lab on chip devices, microfluidic pumps, dosing equipment and other advanced life science systems.