Expanding Flexibility in Biotech Flow Cells with PPSU for Single-Use Applications

Industry: Biotech / Laboratory Instrumentation
Application: Flow Cells in Spectrophotometer Systems
Material Used: Polyphenylsulfone (PPSU)
Services Provided: Precision Machining, Material Recommendation, Compliance Support

Project Overview

A global biotech instrumentation leader partnered with Lehigh Valley Plastics to develop a single-use flow cell alternative to their legacy stainless-steel components. These flow cells are a critical part of spectrophotometer systems, where accurate readings and sterility are essential. While stainless steel remained viable for multi-use environments, labs in GMP-regulated and high-throughput settings increasingly sought disposable options to eliminate the risk of contamination and reduce cleaning validation burdens.

Customer Challenges

• Demand for Single-Use Lab Components: Customers required sterile, disposable options to meet evolving lab protocols and reduce cross-contamination risks.
• Risk of Carryover: Reusable stainless-steel flow cells created potential for contamination between samples, especially in sensitive biological assays.
• Time-Consuming Cleaning: Stainless steel assemblies demanded rigorous post-run sterilization, increasing labor costs and slowing down workflows.
• Dimensional Accuracy: Any replacement plastic needed to exactly match the original metal geometry to preserve spectrophotometric measurement fidelity.

LVP’s PPSU-Based Solution

Lehigh Valley Plastics recommended Polyphenylsulfone (PPSU)—a high-performance, biocompatible thermoplastic—for the new disposable flow cell design. PPSU excels in demanding lab environments thanks to its superior chemical resistance, dimensional stability, and thermal endurance.

Key Advantages of PPSU for Biotech Flow Cells

• Single-Use Ready: Eliminates the need for cleaning and sterilization, minimizing contamination risk and supporting disposable workflows.
• High Chemical Resistance: PPSU resists alcohols, acids, and aggressive sterilants commonly used in biotech laboratories.
• Heat Stability: Withstands autoclaving and other thermal sterilization methods without distortion.
• Regulatory Compliance: Biocompatible and suitable for sensitive diagnostics and biologics testing.
• Precision Machinability: Maintains dimensional accuracy critical to optical systems and flow control.

Results & Outcomes

• Expanded Product Portfolio: The customer now offers both reusable stainless-steel and single-use PPSU flow cells.
• Broader Market Access: Accommodated both traditional labs and those prioritizing disposable workflows.
• Improved Lab Efficiency: Reduced cleaning time led to faster turnaround between assays.
• Reduced Contamination Risk: Single-use PPSU design met strict cleanliness requirements for GMP and diagnostic testing.

By integrating a PPSU-based flow cell into their product lineup, our client met the growing demand for disposable lab components without sacrificing performance. Lehigh Valley Plastics delivered a compliant, high-precision solution aligned with today’s trends in biotech instrumentation and single-use lab systems.

Have a complex component that needs sterilizable, biocompatible performance? Let’s build your next solution together.

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