Scalable, continuous production for high-volume diagnostic consumables.

At BioAnalix, we offer advanced Roll-to-Roll (R2R) microfluidic manufacturing technology to enable the large-scale, cost-effective production of microfluidic devices. This method is ideal for diagnostics companies looking to move from prototype to full-scale deployment — especially in the context of lateral flow assays (LFAs), lab-on-a-chip systems, and biosensor substrates.

Why Roll-to-Roll Manufacturing?

Traditional microfluidic device production (e.g., PDMS molding or injection molding) is often:

Batch-based
Labor-intensive
Limited in scalability

R2R manufacturing offers a continuous fabrication process, which dramatically improves throughput, consistency, and cost-efficiency.

Capabilities of BioAnalix R2R Microfluidic Systems

Capability	Description
Substrate Handling	Processes flexible polymer films (PET, PEN, PVC, etc.) from reels
Precision Printing	Inkjet, screen, or gravure printing of functional layers (hydrophilic coatings, electrodes, antibodies)
Lamination & Cutting	Inline lamination of multilayer devices and precision die-cutting of microchannels
Fluidic Channel Fabrication	Channels created via laser ablation, embossing, or adhesive patterning
Inline Quality Control	Camera inspection and flow testing integrated into production line
Integration Ready	Custom modules for drying, surface treatment, and packaging

Applications

Application Area	Example Use Case
Lateral Flow Assays	Production of COVID-19, RSV, or HIV test strips
Biosensors	Continuous fabrication of glucose, pH, or environmental sensors
Lab-on-a-Chip Devices	Modular devices for sample prep, nucleic acid amplification
Point-of-Care Devices	Disposable diagnostic platforms for decentralized testing
Pharmaceutical QA	Strip-based rapid testing for contaminants and stability markers

Benefits of R2R Manufacturing

Benefit	Impact
High Throughput	Enables 24/7 operation, producing thousands of devices per hour
Cost-Efficiency	Reduced cost per unit compared to injection molding or batch prototyping
Consistent Quality	Automated process reduces human error and variability
Scalability	Ideal for ramping up pilot runs to full industrial-scale production
Design Flexibility	Easily modify patterns and device designs via digital printing methods

Customization & Modular Build

BioAnalix offers modular system configurations tailored to your device design and production volume. Whether you’re scaling an academic prototype or launching a commercial diagnostic strip, our team works with you to:

Select appropriate substrates and adhesives
Optimize printing parameters for reagent deposition
Configure drying, curing, or sealing stages
Integrate final packaging workflows

Sustainability & Innovation

Our platform supports eco-friendly substrates, minimizes material waste through lean design, and enables production of disposable diagnostics with lower environmental impact.

Roll-to-Roll Microfluidic Manufacturing

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