Case Studies


Case Study – Buffer Delivery System


A young life-science company required a buffer solution storage and delivery system for their novel diagnostics platform.

The project was split into two phases – firstly to provide an on-board buffer package with the required shelf life, and secondly, to provide a reliable, repeatable buffer release puncture method.

Both phases were successfully delivered, allowing the company to progress to the next stage of their product development, satisfy investors, and enable further funding.


  • Providing 12 months shelf life of a pre-determined volume of buffer, in a flexible blister pouch with easily punctured lid.
  • Working within a fixed space within an existing device and analysis instrument – into which any additional puncture mechanism would need to be accommodated.
  • Meeting a minimum and maximum puncture force requirement already defined by the analysis instrument.
  • Ensuring products would reliably puncture at point of use, and prematurely during storage and handling.
  • To provide a scalable solution, which indicative production costs for future large-scale manufacture.
In-house assembly of mouldings with puncture needle and sealing mechanism provided an initial batch of pre-production modules for testing of a buffer solution storage and delivery system for a diagnostics platform.
20 cards ready to test
Blister Pouch Compression Test
Bucket 3D prints in bottomless card
Bucket components
Wash Pouch


  • A materials comparison exercise to identify a range of suitable substrates, to go forward to part development and testing based on security of supply, formability, seal-ability, and moisture barrier.
  • Physical testing of materials, partnered with projected calculation of annual moisture loss, to enable a data-driven choice of the best material combination.
  • Functional prototype manufacture, enabling stability testing to demonstrate that initial shelf life was in line with theoretical values.
  • Longer term shelf-life testing carried out whilst the next phase of the project was undertaken.


  • Concept generation of various pierce and burst mechanisms, leveraging experience within FlexMedical team, and engaging industry expertise.
  • Use of 3-D print and Vacuum Cast prototyping to allow quick turnaround of functional tests on concepts, which could be ruled in or out, or modified based on the data.
  • Extensive testing regime to verify design to allow investment in Prototype Injection Mould tooling.
  • In-house assembly of mouldings with puncture needle and sealing mechanism to provide initial batch of pre-production modules for testing.


  • FlexMedical solutions were able to deliver both phases of the project successfully.
  • The empirically measured shelf life conformed very closely to the theoretical calculations initially made, and thus within the value specified by the customer.
  • Modules were shown to puncture within the specified window of applied force.
  • Buffer fluid was delivered to the rest of the device successfully, when required.
  • The customer was able to meet investor milestones.
  • The customer could proceed to the next stage of product development.

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