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Internal Research Project - Gener8
Overview
Overview
This project was a research initiative aimed at automating the silicone oil application process for rotary valves on microfluidic cartridges. The application of silicone oil is crucial for maintaining the performance and longevity of rotary valves, ensuring smooth operation, consistent torque, and minimal wear. The goal is to eliminate the variability introduced by manual oil application and ensure consistent performance across all valves.
Manual Silicone Oil Application Process
My Contribution
My Contribution
I contributed to advancing the project by redesigning and improving the prototype for better consistency and efficiency in oil application. Key improvements I implemented include:
Redesigned Components: Replaced 3D-printed parts with off-the-shelf hardware for smoother movement and enhanced durability of the device's moving components.
Ergonomics & Maintenance: Enhanced the dispensing component with an O-ring to prevent leakage and redesigned it for easier disassembly and cleaning.
Sponge-Stamp Method: Developed a new silicone oil application method, where a sponge is pre-saturated with oil, and the valve is pressed onto it for more consistent and uniform oil distribution, replacing the previous droplet-based method.
Syringe Pump & Arbor Press used for dispensing silicone oil and holding fixturing
Iterative Design & Testing
Iterative Design & Testing
I iterated on the design with two major versions:
V4: Integrated a syringe pump to control the oil flow and reoriented the fixture to ensure the valve presses onto the sponge uniformly.
V5: Replaced flexible 3D-printed arms with rigid metal components for improved precision, optimized the sponge material for better oil retention, and resolved issues with hard-stop fixation.
V4 Sponge Stamp Design CAD (Isometric View)
V4 Sponge Stamp Design CAD (Cross-Sectional View)
V5 Sponge Stamp Design CAD (Isometric View)
V5 Sponge Stamp Design CAD (Cross-Section View)
Achievements
Achievements
Time Study: The new method saved $300 per lot and reduced oil application time by 25 seconds per valve.
Improved Consistency: A weight measurement study showed that the new design provided significantly more consistent lubrication compared to the manual method.
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