How are your microfluidic manifolds used in cell therapy manufacturing?

Microfluidic manifolds are used to route and condition media, buffers, and cells through tightly controlled flow paths during cell selection, activation, washing, transduction, and formulation steps. They help create repeatable shear environments, minimize dead volume, and support gentle mixing so viable cells experience consistent conditions from run to run. In practice, these manifolds are integrated into closed, automated cell-processing systems and benchtop instruments, where they distribute flow between unit operations such as filters, mixers, and reactors while maintaining sterility and precise timing. This supports more standardized workflows for CAR-T, TCR, stem-cell, and other advanced therapies compared with manual, open processes.

What tolerances and channel sizes can you hold for bioprocess microfluidics?

We routinely machine and bond microfluidic features for bioprocess applications with: Critical dimensional tolerances as tight as ±0.005 in on well-supported features. Microchannel widths and depths down into the tens of micrometers, with smooth 3D-surfaced geometries for controlled flow, mixing, and mass transfer. Final tolerances and feature sizes depend on part geometry, materials, and inspection requirements. Share your CAD so our team can confirm manufacturable specs for your design.

Which plastics do you recommend for GMP-adjacent microfluidic manifolds?

For GMP-adjacent microfluidic manifolds, we commonly recommend COC/COP, polycarbonate, PMMA, and other medical- and bioprocess-compatible plastics that offer good biocompatibility and low extractables profiles; compatibility with relevant media, buffers, and cleaning agents; suitable transparency for optical inspection and sensing where needed. Material selection is finalized case by case based on your regulatory strategy, sterilization method (e.g., gamma, EtO, autoclave), and target fluid set. Our team can help compare options for your specific application.

Microfluidic Manifolds & Components

Your Design. Our Expertise.

Work with our engineers to find the right material, process, and cost.

Discuss Your Microfluidic Platform Request Microfluidic Manifold Quote

CUSTOM MICROFLUIDIC COMPONENTS & MANIFOLDS FOR ADVANCED DIAGNOSTIC PLATFORMS

Microfluidics combines science and technology, experimenting with fluid manipulation at the micro level. With this emerging technology, it calls for extensive knowledge of two fields: fluidic physics and micro-engineering. All this to create devices with microscopic footprint and microchannels measuring to micrometers wide.

Controlled Fluidics specializes in crafting custom micro and submillimeter plastic parts and components using state-of-the-art techniques and technology and provide prototype-to-production support for instruments, benchtop systems, and single-use flow paths. With the capability to hold tolerances of ±0.005 inches or better, we ensure precision in every project, catering to the most minuscule operations that save on operating space and cost. Tight-tolerance plastic microfluidics enable precise flow control, low dead volume, and repeatable shear environments, supporting viable cell handling and sensitive assays. Our micromachining and bonding of biocompatible plastics can produce components with microchannels down to ~50 µin and surface finishes as low as 2 RA for controlled cell and reagent handling. Compared to glass or silicon, plastics also offer better biocompatibility, strength (despite size), and easier implementation within systems.

Microfluidic Systems & Design

Our expert teams specialize in designing and producing micro-systems with integrated ports for tubing, filters, sensors, and valves often used in cell processing and bioprocess skids.

Microfluidic Engineering & Development

Our deep expertise in microfluidics produces microscopic components and assemblies that have closed and leak-tight flow paths for sterile/antiseptic processes. We also can replicate flow paths from flow-cell, cartridge, and cassette designs.

Efficient in Time & Budget

Our facilities are one-stop shops. We handle inspection, assembly, and shipment for streamlined convenience and quicker product launches.

ENGINEERING & MANUFACTURING CAPABILITIES

Submillimeter and micro-scale plastics machining with tolerances down to ±0.0005 inches on critical features for precise control of cell residence time, shear, and mixing.

Microfeatures down to ~50 µin with 3D surfacing for smooth, consistent microchannels that reduce trapping, fouling, and cell damage.
Bonded plastic manifolds with complex internal geometries and multi-layer architectures for dense routing of media, buffers, and reagents in a compact footprint.
Direct-from-CAD and 3D-printed model workflows to accelerate design iterations and shorten time to functional hardware.
Process characterization, documentation, and lot traceability aligned with expectations for GMP-adjacent hardware suppliers.

LEARN MORE ABOUT OUR PROCESSES

BIOCOMPATIBLE MATERIALS

Many microfluidics-relevant plastics are stocked for rapid NPI builds, with additional resins quickly sourced through partners to match your regulatory and performance requirements. Such biocompatible, chemically resistant engineering plastics are suitable for:

Contact with typical media, buffers, and process reagents.
Optical detection (e.g., clear plastics for imaging, absorbance, or fluorescence-based readouts).
Sterilization via common methods (EtO, gamma, etc. where supported by the chosen resin)

While microfluidic manifolds can be made from several different plastics, we recommend the following materials for the process: COC/COP, Acrylic (PMMA), PEEK, ULTEM®, PTFE (Teflon®).

SEE MORE MATERIAL OPTIONS

REAL-WORLD MICROFLUIDIC APPLICATIONS

While several industries do benefit from microfluidic devices and manifolds, we find these applications are most common.

CELL THERAPY & CELL PROCESSING

Microfluidic devices for cell enrichment, washing, activation, and viral transduction.
Cartridges and manifolds for automated cell-processing workstations and modular cell therapy platforms.

Designs that help reduce reagent consumption and improve process consistency in CAR-T, TCR, and stem-cell workflows.

BIOPROCESSING & BIOLOGICS

Microscale bioreactors and perfusion modules for media and parameter screening.

Inline sampling, mixing, and conditioning manifolds for upstream and downstream monitoring.
Microfluidic separators and filters to address fouling and shear issues seen in conventional filtration and centrifugation.

PHARMACEUTICAL & CHEMICAL

Microreactors
Micromixers
Droplet generators for formulation development and rapid screening.

RESEARCH & DIAGNOSTICS

Diagnostic cartridges for molecular testing, immunoassays, and point-of-care platforms
Lab-on-chip and organ-on-chip substrates for disease modeling and drug-response studies
Theronostics

AEROSPACE & AERODYNAMICS

Aerodynamic Flow Control

Micropower Generators

Micropropulsion

Astrobiology

Space Exploration

ELECTRONICS, IT, & COMPUTING

Microelectronics Including Microprocessors & Microchips

Cooling Systems

Semiconductors

Flexible Electronic Systems

3D Printers

SPECIAL PROCESSES & PARTNERSHIPS

Accelerated Development & Testing:

We can go from virtual models to bonded plastic manifolds, letting R&D teams iterate channel geometries, mixing strategies, and flow paths quickly. With partner-enabled simulation and test options available, we work to reduce risk in designs before scaling, which then cuts down the number of build-test cycles needed for initial production.

From Prototype to Scale-Up

Our processes support early proof-of-concept through pilot builds and transfer into higher-volume manufacturing once design is finalized. Our services mean that we can do the assembly, inspection, and packaging under controlled conditions for integration into cell-processing instruments, bioprocess skids, and benchtop systems.

Share your cell therapy or bioprocessing flow path to review manufacturability and scalability.

GET MY DESIGN REVIEW

MICROFLUIDIC FABRICATION ARTICLES

Peruse some of our related written works on microfluidics trends and their plastics relationships.

Micro Manufacturing By Tom Rohlfs

MicroMachining Techniques & Assemblies As assemblies and products continue to demand more compact arrangements, micromachining only gets bigger in popularity. Controlled Fluidics is a world class manufacturer of micro machined plastic components.

alternative fuel micro bonded manifold.jpg

Microfluidic Manifolds Podcast: Expert Insights on Design & Applications

In this podcast, gain valuable insights into when and how microfluidic manifolds are used, the materials best suited for their construction, and the specialized processes involved in their fabrication. Discover how these components are revolutionizing applications in life sciences, medical devices, and beyond.

WHAT IS A BONDED MANIFOLD? By Tom Rohlfs

What is a bonded manifold? What they are, why they’re important, and how to tell if you need one *Updated November 10, 2023 If you’ve spent time on our website, you have likely encountered the term “bonded manifold.” But what exactly are those, and do you need one? The field of fluidics often requires smaller…

Meeting the Demands of Laboratory Plastics in Research Settings

See how modern labs rely on advanced plastics engineered for chemical resistance, biocompatibility, microfluidic precision, and sterilization durability. Explore key design and manufacturing considerations for high-performance laboratory components.

No Guesswork. Just Accurate Quotes.

Transparent pricing and lead times built around your requirements.

Get My Custom Quote

MICROFLUIDICS MANUFACTURING