A biotech company required automation of their reagent preparation subsystem within a newly established diagnostic processing laboratory. The project focused on automating the addition of master mix to RT-PCR plates for high-throughput COVID-19 diagnostic testing. The client needed a precision-engineered solution that would increase processing speed and accuracy while maintaining the stringent temperature control and positional tolerances required for biological assays. The system needed to integrate robotic handling, temperature management, and quality control vision systems into a cohesive automated workcell.
The Details
Industry
Medical, Robotics & Industrial Automation
CAPABILITIES APPLIED
The project presented multiple interconnected technical challenges requiring precision engineering and adaptive problem-solving:
Precision Equipment Positioning: Laboratory automation equipment requires exact spatial positioning for robotic interaction. The system needed to maintain positional accuracy within ±30 microns even after maintenance events, initially requiring the six-axis robot to operate without position reteaching after equipment servicing.
Equipment Recalibration and Maintenance Flexibility: While precision nest locating features were initially designed to eliminate robot reteaching after maintenance, client feedback revealed existing recalibration capabilities that allowed design optimization. The solution required balancing ultra-precise positioning with practical serviceability and operational flexibility.
Tabletop Equipment Movement and Registration: Moving laboratory equipment on the workcell tabletop while maintaining precision locating presented mechanical challenges. Equipment needed to be repositionable for maintenance or process changes while guaranteeing return to exact operational positions with sub-millimeter accuracy.
Temperature-Critical Reagent Management: Master mix reagents require strict temperature control to maintain biological viability. The system needed active cooling with real-time temperature monitoring and compensation to prevent degradation during the automated dispensing process, requiring integration of thermal management into the mechanical design.
Precision Liquid Handling and Quality Control: Accurate master mix dispensing to RT-PCR plates demanded precise volumetric control and verification. The solution required integration of load cell feedback for gravimetric verification and vision systems for quality assurance throughout the plate processing workflow.
System Integration Complexity: The reagent preparation subsystem needed to integrate with the broader automated laboratory ecosystem, including conveyance systems, upstream and downstream processing stations, and laboratory information management systems (LIMS).
Re:Build delivered a fully automated reagent preparation workcell that significantly enhanced diagnostic testing throughput and operational efficiency.
The solution featured a custom-engineered frame and tabletop designed for mechanical stability and precision equipment mounting. A pin-based nest locating system provided ±30-micron positional tolerance for laboratory automation equipment. Custom Teflon-coated baseplates with jacking screw mechanisms enabled precise equipment positioning—operators turned jacking screws until locating pins seated into tabletop nests, achieving required positional accuracy before removing adjustment hardware, leaving equipment in exact operational position.
A custom cooling system maintained master mix temperature stability through an integrated plumbing circuit connecting a laboratory chiller to cooling jackets surrounding the labware. Resistance temperature detectors (RTDs) provided real-time thermal feedback, enabling the chiller to compensate for thermal variations and maintain reagents within optimal temperature ranges for biological integrity.
The workcell incorporated a six-axis robot for plate handling automation, integrated with a 3D-printed custom labware holder featuring an embedded load cell for gravimetric verification of master mix dispensing volumes. A sophisticated camera-based vision system provided quality control inspection throughout the process workflow.
The automated system performed the complete RT-PCR plate preparation sequence: peeling plate seals, precisely dispensing master mix reagent, and resealing plates for downstream thermal cycling. Automation eliminated manual pipetting variability and significantly increased processing speed compared to technician-performed operations.
The system successfully passed qualification testing and entered production operation, meeting and exceeding client throughput requirements for high-volume diagnostic testing. Processing efficiency improvements enabled the laboratory to scale COVID-19 testing capacity during critical pandemic response periods.
The modular, adaptable design has enabled continued collaboration beyond the initial deployment. The workcell architecture has been successfully repurposed for additional laboratory processes, and Re:Build continues to provide engineering support for evolving client automation requirements, demonstrating the long-term value and flexibility of the solution.
