As life science devices become smaller, the fluid path is often harder to control. That starts to become noticeable in the fluidic architecture. A layout that works in the lab can be difficult to scale when the device needs to become smaller, cleaner and easier to assemble.
Do you recognize these symptoms?
- Too many tubing connections in a limited footprint
- Variety of manual fittings that reduces consistency
- Dead volume affecting fluid movement
- Cross-contamination concerns or cleaning effort
- Leakage risk across many connection points
- Servicing effort from hard-to-access routing
- Prototype layouts that are difficult to produce at scale
These are not just issues that impact the layout. They can affect ease of cleaning, repeatability, serviceability and production readiness. A diffusion bonded manifold, however, can turn external routing into a compact fluid path inside a bonded plastic manifold.
A diffusion bonded manifold is a compact polymer fluidic manifold made from precisely machined layers. Channel structures are created in the individual layers, which are then aligned and joined using heat and pressure. This creates precise internal fluid paths without needing adhesives for the bond line. The result is a bonded manifold that can route liquids or gases through a compact polymer block instead of relying only on external tubing, fittings and manual connections.
How the technology works:
- Machined layers: Fluid paths, chambers and interfaces are machined into plastic layers.
- Aligned channels: The layers are positioned so channels, ports and functional areas connect as planned.
- Bonded block: The layers are fused into one compact manifold structure using heat and pressure.
- Post-bond machining: Outer geometries and features are machined after the bonding process
- Assembly: Additional products can be assembled and tested to form functional sub-assemblies
This architecture can be relevant for microfluidics, diagnostics and IVD equipment, point-of-care devices, analytical instruments and lab automation where space, routing clarity and quality count.
A diffusion bonded manifold gives you more freedom to design compact, structured fluid paths where space, routing clarity and quality are important.
It can support designs that need:
- Fewer external connections and fittings
- A compact fluid path inside the device
- Lower dead volume and fewer trapped bubbles
- More repeatable assembly steps
- Routing that integrates selected components or interfaces
The right architecture depends on the media, material compatibility, channel complexity, production volumes and the level of integration you need. Explore the first comparison points in our blog.
Application review
We review the application area, media details, target function, available fluidic diagram and project stage to understand what the manifold needs to achieve.
Fluidic architecture discussion
Together, we check whether a diffusion bonded manifold, another fluidic manifold, or a component-based approach is most suitable for the device layout and integration goal.
For a closer look at this particular point, read how to assess a fluidic manifold architecture that fits your application.
Material and interface review
Material selection, routing, channel complexity, valve interfaces and cleaning needs are reviewed against media conditions, production expectations and functional requirements.
CAD and routing concept
Channel routing, layer structure and component placement are developed for review, so your team can assess feasibility before progressing with the design work.
Manufacturing and bonding
Precisely machined plastic layers are aligned and bonded using heat and pressure to create compact internal fluid paths without needing adhesives for the bonding.
Inspection, assembly and testing
Depending on the project scope, Festo can help with inspection, selected assembly steps and testing, including integration of valves, fittings, tubing or pressure control components.
A bonded manifold can do more than route fluids through internal channels. Depending on the project, we can assemble the selected components directly onto the manifold to create a more functional fluidic subsystem. This can include media-separated valves, fittings, tubing or pressure control components. The result is a compact assembly that facilitates clearer routing, has fewer supplier interfaces and offers a quicker path towards production.
This approach is useful when your team wants to:
- Reduce separate assembly steps
- Integrate fluid control components into one compact unit
- Simplify supplier coordination
- Improve repeatability in production
- Review manifold, component and interface design together
The former Carville diffusion bonding technology is now part of our life science manifold range, enabling us to work on compact fluidic architectures for demanding device projects.
What does this mean for your application?
A clearer route from manifold concept to production-ready fluidic assembly as diffusion bonding, engineering advice, component integration and testing expertise are all provided in-house, backed up by quality processes and worldwide support from Festo.
Our diffusion bonded manifolds were nominated for the HERMES AWARD 2026 at the Hannover Messe.
This recognition highlights the credibility of the technology for highly integrated, multilayer polymer manifolds used in advanced microfluidics and life science automation. It also demonstrates that Festo is actively pursuing future concepts and research in this field.
Find out more about how our research in microfluidics is helping make compact fluid control more precise, integrated and scalable.
What is microfluidics?
Microfluidics deals with very small amounts of liquid in compact channels and is often used in diagnostics, lab-on-chip and life science devices. For a more detailed introduction to how microfluidics moves fluids through channels, chips and devices, read our blog on the basics.
What is a diffusion bonded manifold?
A diffusion bonded manifold is a polymer fluidic manifold made from machined layers that are aligned and bonded using heat and pressure. The bonded structure creates a compact block with internal channels that can route fluids.
How does a diffusion bonded manifold work?
Channel structures are machined into individual plastic layers. These layers are aligned and bonded so the internal channels, ports and interfaces are combined into a fluidic architecture.
How is a diffusion bonded manifold different from external tubing or machined manifolds?
Tubing routes fluid externally between components. A machined manifold can route fluid through drilled or milled channels. A diffusion bonded manifold uses bonded plastic layers, which can be used for compact multilayer routing and more complex internal channels.
Can a manifold reduce external tubing and fittings?
Yes, when the design integrates suitable fluid paths inside the manifold. This can reduce tubing connections and make for a more compact assembly. The effect depends on the application and channel design.
Can a manifold help minimize dead volume and trapped bubbles?
The right channel geometry can help reduce dead volume and the risk of trapped bubbles. This must be weighed up against the fluid, flow conditions, cleaning process, and device layout.
Which materials can be used for diffusion bonded manifolds?
Common options include PMMA / acrylic and PEI / ULTEM. The choice of material depends on media compatibility, temperature, exposure time, optical clarity, cleaning process and production requirements.
Can valves and other components be assembled onto the manifold?
Yes, selected integrated fluidic assemblies can combine the manifold with components such as media-separated valves, fittings, tubing and pressure control components. The exact assembly depends on the application.
Which life science applications use diffusion bonded manifolds?
Relevant areas include diagnostics and IVD equipment, point-of-care devices, lab automation, analytical instruments, lab-on-chip, drug screening, RNA/DNA sequencing, dialysis, tissue engineering and organ-on-chip.
Does every compact fluidic system need a diffusion bonded manifold?
No. Some applications are better served by external tubing, machined manifolds, molded components, 3D printed routes or a different fluidic architecture. A project assessment helps define the best fit.
What information does Festo need to assess a manifold project?
Helpful inputs include the application area, media details, fluidic diagrams, flow and pressure requirements, volume targets, material preferences, prototype status, production timing and any need for valves, fittings, tubing or testing.
Our free design guide helps you prepare these details before the project assessment.
How is Carville connected to Festo?
Festo has acquired the former Carville diffusion bonding technology. With this additional capability now part of the Festo brand, diffusion bonded manifold projects can also be supported, combined with engineering support, component integration and global support.