Meeting the Unique Demands of Laboratory Plastics in Research Settings

Laboratory plastics have evolved dramatically in recent years, driven by advances in microfluidics, diagnostics, and medical research applications. As engineers developing components and devices for these demanding environments, understanding the specific material and manufacturing requirements is crucial for success. Where it stands right now, the current market for  laboratory plasticware is valued at approximately $2.13 billion due to its advancements and comparable properties with other traditional materials. Moreover, it is projected to grow at a CAGR of 4.8% through 2030, reflecting the increasing sophistication and precision demands of modern research settings.  

While we have an  in-depth white paper about designing specifically plastic labware, this article here gives some precursory information about laboratory plastics and their unique situations, like an adjoining document to that white paper. We’ll start by sharing some key concepts that are integral to understanding laboratory plastics and meeting their requirements.  

Dimensional Accuracy & Consistency 

Laboratory applications demand exceptional precision in manufactured components, particularly for  microfluidic devices. Here, dimensional variations can significantly impact flow characteristics and analytical outcomes. Modern microfluidic systems require channel geometries with tolerances measured in micrometers, requiring advanced manufacturing techniques and particular quality control processes. Not all plastics can handle the microfluidic production process or function to serve microfluidic device needs. The intensely precise machining of microscopic and complex internal geometry can relegate some plastic materials away from not only microfluidics but plastic labware as a whole.   

However, many thermoplastics like PMMA and some specialized engineering plastics offer superior dimensional stability and are ideal candidates for precision CNC machining approaches for microfluidics and other labware. CNC machining provides exceptional control over dimensional tolerances, with modern multi-axis machines capable of achieving tolerances within micrometers for medical-grade plastic components. This subtractive manufacturing method allows engineers to create complex geometries with consistent surface finishes while maintaining the material integrity essential for laboratory applications. 3D printing still has a place, however, due to the limited options of materials that can handle the process and the lack of refined precision, this confines 3D printing to particular use cases that often fall outside of microfluidics and some labware.  

USP Class VI Certification & Testing 

For laboratory plastics that may contact biological samples or pharmaceuticals, USP Class VI certification represents the gold standard for biocompatibility. This rigorous testing protocol requires a few different types of tests. First, there are multiple extraction tests using different solvents (saline, alcohol solutions, polyethylene glycol, and vegetable oil) followed by systemic injection, intracutaneous, and implantation tests. The testing evaluates whether materials release cytotoxic compounds when in contact with these different chemicals that could interfere with cell cultures or pose safety risks in medical applications.  

USP Class VI certification is particularly important for plastic manufacturers supplying components to  pharmaceutical and biotechnology companies, where even trace leachates can compromise experimental results or regulatory compliance. Fluoropolymers typically achieve Class VI certification due to their chemical inertness, while many commodity plastics require specialized formulations and additives to meet these stringent requirements. Using another type of material when a product calls for a USP Class IV certified material could result in inaccurate data, system failure, and/or other much more dire consequences. 

ISO 10993 Biocompatibility Assessment 

Multi-Modal Sterilization Requirements 

Laboratory plastics must often withstand multiple sterilization methods throughout their operational lifetime, each presenting unique material challenges. Steam autoclaving at 121-134°C remains the most common sterilization method but is incompatible with many thermoplastic materials. Materials suitable for autoclaving include polypropylene, PVDF, PTFE, and specialized high-temperature polymers. Others like polycarbonate, polystyrene, and standard polyethylene will deform or fail under autoclave conditions. 

Gamma radiation sterilization (typically at doses of 25-50 kGy) offers an alternative for heat-sensitive materials. However, it can cause polymer degradation, discoloration, and mechanical property changes. Engineering considerations must account for these effects, particularly for precision components where dimensional changes or surface modifications could impact performance. Ethylene oxide (EtO) sterilization provides a low-temperature alternative but requires materials that can withstand gas exposure and subsequent aeration cycles without absorbing toxic residues. 

Repeated Sterilization Cycles 

Many laboratory applications require components capable of withstanding hundreds of sterilization cycles without significant degradation. This requirement particularly impacts reusable laboratory instruments and high-value components where replacement costs are significant. Materials selection must consider cumulative effects of repeated thermal, chemical, or radiation exposure, often requiring accelerated aging studies to predict long-term performance.  

Trace Metal Leaching & Analytical Interference

For trace analysis applications, plastic components must minimize leaching of metallic contaminants that could interfere with analytical measurements. All plastics release trace amounts of common metals when exposed to acid preservatives typically used in analytical chemistry.  Here is when specialized polymer formulations are absolutely essential for applications requiring detection limits in the ng/mL range. Through combining certain polymers to complement their strengths, wear slows down due to degradation or other processes from harsh chemical use.  

Recent validation studies demonstrate that even certified materials can vary significantly in their metal content. That is why complete acid digestion protocols are necessary to establish baseline contamination levels. Engineers developing components for trace analysis must work closely with analytical chemists to establish acceptable contamination limits and validation protocols. This not only ensures a device’s longevity but also their safety.  

Surface Properties & Protein Adsorption 

In biological applications, surface properties and features can come to the forefront to prevent protein adsorption and maintain analytical accuracy. Polycarbonate surfaces, while optically transparent and easy to fabricate, can suffer from hydrophobic protein absorption. That absorption may compromise microfluidic device performance, if not properly treated through  surface modification techniques. These can include techniques like plasma treatment, chemical grafting, and specialized coatings. These are increasingly necessary to achieve the hydrophilic, non-fouling surfaces required for reliable biological assays. Without them, it again would have serious adverse consequences not only to data and device itself but potentially also another living entity.  

The challenge extends beyond simple hydrophilicity to include surface charge, roughness, and chemical functionality that can be tailored for specific biological interactions. Advanced surface modification techniques allow engineers to create surfaces that actively repel specific proteins while promoting desired interactions, enabling more sophisticated analytical device functioning. 

The development of laboratory plastics for modern research applications requires a sophisticated understanding of material science, manufacturing processes, and analytical requirements. Success depends on carefully balancing chemical resistance, precision manufacturing, biocompatibility, sterilization durability, and contamination control. As research applications become increasingly demanding and regulatory requirements more stringent, the expertise required for effective laboratory plastic component design continues to expand. 

The growing sustainable laboratory plasticware market, projected to reach $2.69 billion by 2035, also introduces additional considerations around recyclability and environmental impact without compromising performance. Engineers must now consider end-of-life scenarios and circular economy principles while maintaining the exacting standards required for research applications. 

By understanding these five critical areas and their interdependencies, engineers can develop laboratory plastic components that not only meet current requirements but anticipate future needs in a rapidly evolving research landscape. The key to success lies in early collaboration with end users, rigorous testing protocols, and a thorough understanding of the specific analytical and operational requirements that define each application.