Lab-on-a-chip: the future of diagnostics
Lab-on-a-chip technology is transforming allergy diagnostics, and SCHOTT MINIFAB is laying the groundwork for the innovative technology to go mainstream.
Lab-on-a-chip technology is revolutionizing diagnostics with faster, safer, and more precise testing for allergies and beyond.
- Traditional allergy testing is often invasive, imprecise, and emotionally taxing. Lab-on-a-chip technology offers a safer, faster, and more accurate alternative.
- Using microfluidic systems and microarrays, lab-on-a-chip devices analyze a tiny blood sample against multiple allergens, eliminating direct exposure risks.
- This technology extends to real-time disease detection, making diagnostics more accessible, affordable, and efficient.
- SCHOTT MINIFAB accelerates commercialization with modular design solutions, helping bring advanced diagnostics to more people.
“All I could think was, ‘What is happening? Is he going to be okay?’” says Max, now 38. His parents rushed his brother to the hospital, leaving Max behind, terrified and helpless. That day marked the beginning of a long and arduous journey for the Shak family—a journey defined by endless medical tests, dietary restrictions, and a constant vigilance that overshadowed every meal.
Though having a food allergy may sound simple, Max’s family came to the same conclusion of many who undergo the often imprecise and frustrating process. There are two leading diagnostic tests used to find exactly what someone might be allergic to – both of which involve introducing allergens to the patient in tiny doses, then seeing what kind of reaction they have.
“The process felt primitive,” Max reflects. “It’s almost like playing with fire. The emotional toll it took on my family was immense.”
That's where lab-on-a-chip technology comes into play. As a researcher and science writer, Max deeply understands how the groundbreaking innovation could not only provide a solution to the challenges of allergy testing, but transform the entire field of diagnostic medicine.
“Lab-on-a-chip technology holds immense promise in changing this scenario for millions of families like mine,” Max says. “The idea of performing an allergy test through a simple, quick, and minimally invasive process—not only more affordable but also much more accurate—is a game-changer.”
The long road to personalized diagnostics
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To this point, medical professionals largely rely on two different types of diagnostic tests to find exactly what someone is allergic to. “Both boil down to a process of elimination—constant trial and error,” Max explains.
Like many seeking to identify the source of their allergies, Max’s brother first underwent a series of skin prick tests. Here, a medical professional introduces potential allergens to the patient’s skin via dozens of tiny needles. “My brother went through countless skin-prick tests to determine the root cause,” Max says. “For a young kid it was overwhelming, and for our family, the inconclusive results or misdiagnoses took an emotional toll.”
The next leading allergy test involves a series of “oral food challenges.” Here a patient is given small amounts of potential allergens, under medical supervision, to see if their body can tolerate them. “It was nerve-wracking each time, knowing that even a small amount could trigger a serious reaction,” Max recalls. “His diet became so restricted that grocery shopping turned into reading labels obsessively and cooking meals from scratch to avoid cross-contamination. It’s exhausting, but necessary.”
Today, thanks to the advancement of microfluidic systems, Max’s family could have determined his brother’s allergy with a mere drop of blood.
Wladimir Bulgar via Getty Images
“Microfluidic systems are relatively small, enclosed devices that replicate complex laboratory processes,” explains Cristian Zambrano, product development scientist at SCHOTT MINIFAB. “They can mix components, detect biomolecules, and perform chemical reactions, all while using minimal volumes of reagents and samples.” Hence the reason for the name, “lab-on-a-chip” technology.
By integrating microarrays—tiny grids containing multiple types of allergens—with microfluidic systems, it becomes possible to test a patient’s blood against numerous allergens simultaneously. “This approach eliminates the need for direct exposure to allergens, making the process safer and less invasive,” Cristian notes.
This efficiency is a game-changer. Traditional diagnostic methods often require significant resources and time, limiting accessibility and driving up costs. In contrast, lab-on-a-chip devices are designed to be user-friendly, fast, and highly replicable, making advanced diagnostics more affordable and widely available.
To be sure, this technology has broad applications in diagnostics. One of the leading diagnostic tools for the last few decades is next-generation sequencing (NGS), which is efficient at reading DNA sequences to find genetic risk factors for diseases but doesn’t tell us much about how the body is functioning in real-time. “Microfluidics, on the other hand, can help in the design of point-of-care devices to detect not only DNA or RNA,” Cristian explains, “but also proteins and their post-translational modifications, or metabolites that are associated with a particular condition.”
In other words, because microfluidics can help detect proteins and other biological markers that reveal real-time changes in the body, lab-on-a-chip technology stands to become a powerful tool for faster, more accurate disease diagnosis and monitoring.
The challenges of going from lab to market
Though the science behind lab-on-a-chip technology is groundbreaking, the path to commercialization is equally critical. But bringing lab-on-a-chip technology to market has historically posed several key challenges, from design complexity to manufacturing scalability. “Many innovations start in a research lab, where they work on a benchtop scale,” explains James Downs, SCHOTT MINIFAB’s VP of Business Development. “The challenge is shrinking these systems into a small, functional, and affordable microfluidic consumable.”
This miniaturization requires expertise in fluid dynamics, materials science, and precision engineering. Lab-on-a-chip devices need specialized components such as microchannels, coatings, sensors, and valving systems, all of which must be integrated seamlessly.
It follows, then, that taking an innovative lab-on-a-chip device from prototype to production also poses challenges. “There are countless potential pitfalls—bubble formation, backflow issues, or material incompatibilities—that can derail production,” Downs notes. “Addressing these early is key to ensuring a successful transition to mass production.” Traditional microfluidic production methods can be expensive and time-intensive, limiting scalability.
And to top it all off, the cost constraints of point-of-care diagnostics mean that devices must be produced affordably to meet market demands. “Considering the insurance reimbursement systems in place, a point-of-care test might sell for just a few dollars, so production costs have to be tightly controlled,” Downs explains.
Laying the groundwork for scalable innovation
To address these challenges, SCHOTT brought everything from integrating design to development and manufacturing under one roof. “This field is complicated enough, and trying to coordinate all the different aspects of bringing an innovative idea to market stood as an impediment to lab-on-a-chip technology thriving,” James says. “It's taken a long time and a lot of work, but we’ve brought everything under one roof in order to provide a seamless transition from concept to commercialization.”
One key advantage is SCHOTT MINIFAB’s rapid prototyping capabilities. Using milling and 3D printing, the team can quickly test and refine designs to identify potential risks before committing to full-scale production. This iterative approach allows companies to fine-tune their devices while maintaining cost efficiency.
Additionally, SCHOTT MINIFAB’s expertise in polymer injection molding and microarray integration enables precise, high-quality production tailored to each client’s needs. “We bring together automation engineers, bioscientists, and quality specialists from day one,” James explains. “This ensures that every design decision is informed by the end goal—scalable, high-performance diagnostics.”
By focusing on early-stage risk mitigation and leveraging multidisciplinary expertise, SCHOTT MINIFAB streamlines commercialization, paving the way for lab-on-a-chip devices to become more accessible and cost-effective for real-world applications.
A vision for the future
The potential of lab-on-a-chip technology extends far beyond its current applications. As precision medicine gains traction, the ability to tailor diagnostics and treatments to an individual’s genetic makeup, environment, and lifestyle becomes increasingly important. “Bioscience is the key to addressing complex healthcare challenges,” Cristian emphasizes. “Microfluidic devices will need to evolve to meet these demands, and SCHOTT MINIFAB is here to support that evolution.”
For Max, the promise of lab-on-a-chip technology represents more than scientific progress—it’s a beacon of hope. “I think about future generations—my own kids, maybe—and how much I hope they never have to go through what my brother did,” he says. “This isn’t just about making things easier -- it’s about restoring normalcy and safety for millions of people.”
As lab-on-a-chip technology continues to advance, the revolution in diagnostics is just beginning. From allergy testing to precision medicine, these tiny devices are poised to make healthcare more accessible, efficient, and compassionate. The future of diagnostics is here, and it fits in the palm of your hand.
