Automation of organs-on-a-chip for drug development

Automated production of organs-on-a-chip: Together with experts from TU Darmstadt, Festo has developed a solution that demonstrates the automated production of organs-on-a-chip. © Festo SE & Co. KG

Bioprinter for organs-on-a-chip: The bioprinter prints living cells embedded in hydrogel in tiny droplets directly onto the microfluidic chip.

Microfluidic chip: The microfluidic chip: a diffusion bonded manifold with precise channel structures.

SupraMotion transport System: Contactless transport with SupraMotion: electric axes under the floor surface move the cryostat and the magnetic carrier hovering above it from station to station.

The development of drugs is lengthy, complex and expensive. Approaches from organ-on-a-chip research promise to shorten the time to approval of new active ingredients. Together with experts from TU Darmstadt, Festo has developed an exhibit that demonstrates the automated production of such mini-organs: A bioprinter applies human cell material to a microfluidic chip, on which organ-like tissue then grows. Festo is combining two future technologies for the first time: SupraMotion and Diffusion Bonded Manifolds.

The development of drugs takes a long time and is very costly: a drug candidate first undergoes several preclinical studies on cell cultures or animals. Clinical trials on humans follow in the final phase before authorisation. In this phase, an average of five drug candidates are tested per drug, four of which fail in the end - so-called late fails. The reason for this is that the results of preclinical studies often do not translate well to the human organism.

Much better results are achieved with so-called organs-on-a-chip from the bioprinter, on which efficacy and side effects can already be tested more precisely in the preclinical studies. Unsuitable candidates are thus eliminated at a much earlier stage, saving time and money. Organ-on-a-chip (OoC) refers to microfabrication processes that are used to create miniature models of organs such as the heart, lungs or intestines. Cells are arranged and cultivated on prefabricated polymer or plastic carriers in such a way that they form organ-like tissue.

Precise fluid control for tissue engineering

Together with experts from TU Darmstadt, Festo is demonstrating how the bioprinting process can be automated - including a solution for the contactless transport of microfluidic chips equipped with bonded manifold technology. Bonded manifolds are multi-layered plastic manifold plates with finely structured microchannels that enable the precise dosing and handling of liquids.

SupraMotion: contactless working in the laboratory of the future

Transport through the various steps in the production process is carried out using Festo's unique superconductor technology. This allows objects to be transported contactlessly on a magnetic levitator. The kinematic system remains outside the clean room and does not carry any particles away. The surfaces are kept clean and are easy to clean. The innovative technology can be combined with automation solutions for the life science sector to create a reliable overall concept that fulfils the highest cleaning and cleanliness requirements.

Diffusion Bonded Manifolds from Festo: Nominated for the Hermes Award 2026

Festo is among the three nominees for the Hermes Award 2026 with its Diffusion Bonded Manifolds. The Hermes Award is one of the world's most prestigious industry prizes and is presented at the Hannover Messe for outstanding innovation - products and solutions with a particularly high degree of technological innovation.

Festo as an automation partner for life sciences

With flexible automation solutions, Festo supports the transfer of innovative therapies into clinical practice and makes state-of-the-art biotechnology available where it is needed. With the help of its product portfolio of pneumatics, electrics, software and AI, Festo realises the perfect seamless automation solution together with the customer.