We are seeking a highly skilled Microfluidics Engineer to drive the development of next-generation diagnostic consumables using 3D printed prototypes and translating these into injection moulded designs. You will be responsible for translating complex fluidic designs into high-volume, manufacturable products using precision injection moulding, laser welding, and high-speed assembly processes.
Contribute to an effective research and development service, supporting other functions and partners to investigate and resolve technical challenges for the commercial benefit of the business.
This role will be at an Engineer 2 level and will be in the Research and Development department.
Key Responsibilities
- Design & Simulation: Design complex microfluidic architectures (channels, mixers, valves, and reservoirs) using CAD (SolidWorks/AutoCAD) and perform CFD (Computational Fluid Dynamics) simulations to optimize fluid flow.
- Design & Experimentation: To work with the scientific team and translate assay workflow steps into a fully automated workflow. Designing rigs, prototypes and experimental set-ups for testing.
- Design for Manufacturing (DfM): Adapt R&D-scale designs for high-volume injection moulding. This includes managing draft angles, wall thickness, surface finishes, and tool inserts.
- Material Selection: Evaluate and select medical-grade polymers (e.g., COC, COP, PMMA, PC) based on optical clarity, biocompatibility, and chemical resistance.
- Prototyping & Tooling: Oversee the fabrication of prototype moulds via micro-milling or 3D printing and manage the transition to multi-cavity production tooling with external vendors.
- Assembly Integration: Develop robust bonding and sealing strategies, including ultrasonic welding, laser welding, and the integration of pressure-sensitive adhesives (PSA).
- Verification & Validation: Execute rigorous testing protocols to validate fluidic performance, including burst pressure testing, flow rate characterization, and shelf-life stability.
- Cross-Collaboration: Collaborate with assay scientists to ensure compatibility between fluidics and biological chemistry. Collaborate with design engineers to facilitate interface design between test cartridge and instrument under development.
Position in the Organisation:
- Operates alongside the scientific teams and external vendors to deliver cross functional projects.
Knowledge, Skills & Experience
Essential:
- Polymer Processing: Deep understanding of the injection moulding process, including cycle time optimization, tool cooling, and the impact of moulding parameters on micro-feature fidelity.
- Metrology: Experience with high-precision metrology tools (e.g., SEM, white light interferometry, or CMM) to verify micron-scale features.
- Surface Chemistry: Knowledge of surface modification techniques (e.g., plasma treatment, hydrophilic coatings) to control capillary flow and protein binding.
- Fluidic Fundamentals: Expertise in microfluidic flow systems, capillary action, and droplet microfluidics.
- Problem Solving: A proven track record of troubleshooting moulding defects (warpage, flash, short shots) in micro-scale parts.
- Education: B.Sc./M.Sc. or Ph.D. in Mechanical Engineering, Physics, Biomedical Engineering, Materials Science, or a related field.
- CAD: High proficiency in CAD and finite element analysis software.
- Data analysis: Strong data analytics skills required with proficiency in statistical software packages (such as Python, MATLAB, R) for robust analysis of fluidic performance and interpretation of biosensor test data to support evidence-based development of test cartridges.
Desirable:
- Experience: 3–5+ years in the medical device or IVD (In Vitro Diagnostics) industry, specifically working on plastic consumables.
- Regulatory Knowledge: Familiarity with ISO 13485 and FDA QSR environments.
- Experience with Screen Printed Electrodes (SPEs), Laser ablation or integrating biosensors into plastic housings.
- Rudimentary knowledge of electronics is desirable to support integration with sensor interfaces, prototype test rigs and diagnostic instrumentation.
- Knowledge of biological assay workflows including immunoassay and molecular-assay based formats.
- Knowledge of automated reagent loading and lyophilization beads.
- Experience managing CMO (Contract Manufacturing Organization) relationships in the UK or abroad.
- Experience in an IVD company.