Microfluidics: the key to next-generation medical technology
Diffusion-bonded manifolds are used in both CAR-T cell therapy and organ-on-a-chip applications. They are multi-layered polymer distribution plates capable of controlling, dispensing, mixing and sensing liquids. Unlike conventional manifold duct plates, which primarily have passive distribution functions, our manifolds integrate active functions within a very compact footprint. These include optimised mixing channels, media-separating valve technologies with minimal dead volume, and built-in sensors for temperature, flow, pressure, colour, pH‑, etc.
The technical innovation lies in the combination of finely structured, multi-layered microchannels, integrated valve and dispensing components, and directly embedded sensor measurement points. The way the process is designed means that the components are cost-effective to manufacture in series. This results in more compact and reliable systems that are easier to validate and can be used in biotechnology, medical and semiconductor applications.
The diffusion bonded manifolds were nominated for the Hermes Award 2026. The award is one of the world’s most prestigious industrial prizes and is presented annually at the Hannover Messe for outstanding innovations.
From capillary forces to pressure-over-liquid
Just as in nature, capillary forces alone are not enough to carry liquid all the way to the very tip of the leaf; it rises only slightly above the water level. Whilst nature creates a vacuum through evaporation, in this exhibit we create it using a precisely controlled vacuum. This draws the liquid through the bonded manifold. The system is then drained again using pressure-over-liquid, creating a cycle.
High-precision dispensing
Liquids are pumped through a diffusion bonded manifold manufactured by Festo according to a predetermined pattern, and with two media-resistant valves in precisely synchronised operation. This demonstrates how liquids can be dispensed with great precision.
Liquid handling in the laboratory environment
96 samples are dispensed quickly and precisely into a microtitre plate using an eight-channel dispense head. One of these samples is then divided into many small samples using microfluidics. The process is examined under a microscope. The entire system is then drained again.
Sensor integration
Festo demonstrates how the manifold channel structures are used for mixing and analysing liquids. The integrated flow and pressure sensors ensure stable operation. When liquids are mixed, the colour changes and this change is detected by the optical sensors. Air bubbles deliberately injected into the system are detected and automatically removed.
Integration of pneumatic valves
The pneumatic diaphragm valves that are integrated into the manifold control two different fluids, which flow to the individual letters of the Festo logo via a pressure-over-liquid system. The diaphragm valves are actuated by an external valve terminal connected via a compressed air interface.
Diffusion bonded manifolds: precision fluidic solutions for the most demanding applications
Diffusion bonded manifolds combine precise channel structures and a contamination-free connection of the individual layers with a compact design. This is made possible by HADB (high accuracy diffusion bonding) technology, which is used to manufacture acrylic and ULTEM manifold duct plates with maximum precision. In combination with the media-separated valves of the VYKA, VYKB and VYKC series, Festo is able to offer microfluidic solutions from a single source.
Festo – your automation partner for the life sciences sector
The flexible automation solutions offered by Festo support the transfer of innovative therapies into clinical practice and make state-of-the-art biotechnology available where it is needed. We have an extensive range of products, but also develop customised solutions for laboratories, diagnostic and bioprocess applications, from precise liquid and gas dosing to scalable, modular systems. Drawing on our product portfolio of pneumatics, electrical systems, software and AI, we work with our customers to deliver the perfect seamless automation solution.