Production and Assembly of the BP7 Micropump

From layered precision to reliable performance

Introduction: How Performance Is Engineered

Behind the compact form and high precision of the BP7 micropump lies a carefully developed production process. It combines microfabrication, advanced materials, and rigorous testing to ensure every unit performs exactly as intended.

This article provides an inside look at how the BP7 micropump production process works, including assembly, polymer laser welding, and 100% end-of-line quality control.

Step-by-Step: BP7 Micropump Assembly

The BP7 is built from multiple microstructured layers, stacked bottom to top. Each layer serves a specific function in fluid control, actuation, or system integration.

Let’s break it down.

1. Main Body

• Forms the foundation of the micropump
• Includes fluidic interfaces and half of the internal channel structure
• Made of laser-transparent polymer for through-transmission welding
• Offers mechanical support and integration options for tubing

2. Flap Valve Sheet

• Flexible, microstructured polymer sheet
• Functions as a passive check valve
• Positioned between upper and lower fluidic channels
• Ensures unidirectional flow and tight sealing between cycles

3. Middle Layer

• Defines the pump chamber geometry
• Holds the valve sheet in place
• Contributes to the BP7’s precise stroke volume
• Chamber height: 120 µm | Diameter: 10 mm
• Enables small-volume fluid handling with high efficiency

4. Actuator Assembly

• Preassembled sheet with two piezoelectric bending actuators
• One actuator per pump chamber
• Transfers motion to the fluid with high energy efficiency
• Seals the chamber from above while allowing dynamic actuation

5. Electrical Connection

• Each actuator is soldered to a flexible 4-lead cable
• Separate positive and negative lines for both actuators
• Cable design supports durable integration and flexible mounting
• Optimized for lab setups, OEM modules, or mobile applications

6. Top Lid

• Polymer cap pressed onto the full stack
• Finalizes the mechanical enclosure
• Laser-engraved with:
  • Product name
  • Unique serial number
  • QR code for traceability

This completes the core of the BP7 micropump production process.

Polymer Laser Welding: The Key to Adhesive-Free Assembly

One of the most innovative elements of BP7 production is the use of polymer laser welding as a clean, fast, and precise method for joining plastic parts.

Why Laser Welding?

• No adhesives → no contamination or curing time
• Creates hermetic seals resistant to chemicals and pressure
• Localized heating avoids warping or damaging microstructures
• Enables tight tolerances, ideal for microscale components

Why Transparent Materials?

• Laser welding uses the through-transmission method
• Laser passes through the transparent top layer (e.g. the main body)
• Absorbed by the darker lower layer, causing localized melting
• Only the interface bonds, outer surfaces remain stress-free
• Critical for protecting delicate valve components inside

End-to-End Quality Testing

Assembly is only one part of BP7 micropump production. Each unit is tested in several stages to ensure full functionality and reliability.

1. Leak Testing

• Performed after laser welding
• Pumps are pressure-tested at 500 mbar
• Ensures fluidic seals are tight and robust
• Failed units are reworked or rejected

2. Electrical Verification

• Tests all four piezo contacts for:
  • Continuity
  • Correct polarity
• Verifies that both actuators are fully functional

3. Labeling & Traceability

• Every pump is engraved with:
  • Unique serial number
  • Scannable QR code
• Enables tracking throughout manufacturing and customer lifecycle

4. Functional Testing

• Each BP7 goes through 100% end-of-line functional testing
• Tested with both air and water
• Recorded parameters:
  • Maximum flowrate
  • Maximum backpressure
• Logged into internal database for traceability

Engineered for Reliable, Scalable Performance

The BP7 micropump may be compact on the outside, but behind every unit is a highly engineered production process. From laser-welded layers to automated quality checks, each step is designed to ensure precision, consistency, and reliability at scale.

By combining advanced polymer processing, smart mechanical design, and rigorous end-of-line testing, the BP7 delivers what modern microfluidic systems demand:

• Compact structure
• Repeatable performance
• Full traceability
• Scalable production

That’s what makes the BP7 more than a component. It’s a production-grade microfluidic solution.