Development of an Automated Reagent Dispensing Machine for PCR Testing

Project overview

AUTOMATING REAGENT DISPENSING FOR PCR TESTING

During the COVID-19 pandemic, laboratories faced increased demand for PCR testing and the associated preparation of reagents. KVAZAR developed a custom automated dispensing machine designed to improve the speed and consistency of filling laboratory plates and multi-row containers.

THE ENGINEERING CHALLENGE

The machine had to dispense reagents into containers with 4 to 8 rows while providing a dosing resolution of 1 µL.

Accurate dispensing required more than selecting a precision syringe. The system needed reliable positioning of containers beneath the dosing unit, synchronized activation of the dispensing mechanism, stable mechanical alignment, and minimal vibration during operation.

Another important requirement was the ability to replace the dosing syringe without introducing backlash into the mechanism.

MECHANICAL ENGINEERING

KVAZAR designed the machine frame and positioning mechanisms around these requirements. The structure was developed to maintain alignment and reduce vibration during the dispensing process.

A dedicated mounting mechanism was engineered for the Socorex Dosys Premium 164 syringe, with a volume range of 0.5–5 mL. The mount allows syringe replacement while maintaining the mechanical stability required for precision dosing.

CONTROL SYSTEM AND SOFTWARE

The machine supports different laboratory container configurations. Operators can select the required plate type through the control panel and adjust the movement speed between individual cells.

Custom-developed software accounts for errors arising during dispensing and corrects the operation of the mechanical systems to maintain accurate filling.

PROJECT RESULTS

The resulting machine accelerated reagent dispensing for PCR testing and supported continuous operation without loss of dosing accuracy.

The project demonstrates KVAZAR's ability to combine precision mechanical engineering, automated positioning, laboratory equipment integration, and custom software into a purpose-built industrial system.

The challenge

Develop a machine for automated reagent dispensing into laboratory plates and other multi-row containers used in PCR testing. The equipment had to support containers with 4 to 8 rows and provide a dosing resolution of 1 µL. The objective was to accelerate reagent filling while maintaining dosing accuracy during continuous operation.

Constraints

The equipment required precise positioning of laboratory containers beneath the dispensing unit and synchronized activation of the dosing mechanism. The mechanical structure had to maintain alignment and minimize vibration during filling. The syringe mounting system needed to allow replacement without introducing mechanical backlash. Different container configurations and adjustable positioning speeds also had to be supported.

Our solution

KVAZAR developed an automated dispensing machine integrating a precision positioning mechanism, a rigid mechanical structure, a replaceable syringe mounting system, and dedicated control software.

A Socorex Dosys Premium 164 syringe with a volume range of 0.5–5 mL was selected as the dosing device. The mechanical mount was designed to permit syringe replacement while preventing backlash.

The operator interface allows selection of different laboratory plate configurations and adjustment of movement speed between cells. Custom control software accounts for dispensing errors and adjusts the mechanical system's operation to maintain accurate filling.

Implementation

1. Analysis of laboratory container configurations and dosing requirements.
2. Development of the machine layout and precision positioning system.
3. Design of a mechanically stable frame to maintain alignment and minimize vibration.
4. Engineering of a replaceable syringe mounting mechanism without backlash.
5. Integration of the Socorex Dosys Premium 164 dosing syringe.
6. Development of an operator interface for container selection and movement speed adjustment.
7. Development of control software with dispensing error compensation.
8. Manufacturing and implementation of the automated dispensing equipment.

Technical details

Equipment: Automated laboratory reagent dispensing machine
Application: PCR testing reagent dispensing
Supported containers: Laboratory plates and multi-row containers
Container configurations: 4–8 rows
Dosing resolution: 1 µL
Dosing device: Socorex Dosys Premium 164
Syringe volume range: 0.5–5 mL
Positioning: Automated container positioning beneath the dispensing unit
Operator controls: Container type selection and adjustable movement speed
Mechanical design: Vibration-minimized structure and backlash-free syringe mounting
Software: Custom control system with dispensing error compensation

The result

The developed machine accelerated the process of dispensing reagents into laboratory plates for PCR testing. It also enabled continuous reagent filling without loss of dosing accuracy. This capability was particularly important during the COVID-19 pandemic in 2021, when laboratories faced increased demand for testing operations.

Services

Engineering for your task. ↗