The project aims at a holistic new design strategy, coordinated pilot lines and business model for the prototyping, fabrication and commercialization of polymer-based microfluidic systems. It stems from the recognition that a microfluidic chip is a key part of a microfluidic MEMS, but only a part. Many limitations to fast prototyping, industrialization and ultimate performances lie not in the chip itself, but in the world-to-chip connections and integration of multiple external components. We shall address in a single strategy the streamlined construction of whole microfluidic systems, starting from existing pilot lines in injection moulding, 3D printing and instrument construction. This will specific innovations. First, the resolution of 3D printing will be increased by a factor at least 10, down to 1~3µm, with a throughput 10 to 100x higher than that of current high resolution 3D printing machines, to support the flexible production of chips with complex 3D architectures. New soft, bio, environment-friendly and/or active materials will be integrated in the production chain using a technology patented by the partners. Large-scale markets requiring mass production at the lowest cost will be addressed by a fully integrated pilot line, streamlining injection moulding of raw chips, reagents and components integration, sealing and quality control. Inter-compatibility between 3D printing and injection moulding, regarding architectures and materials, will be developed to accelerate the prototype to product value chain. After development and upscaling, the technology will be demonstrated and qualified in operational environment by end-users with lab-on-chip applications in health (cancer diagnosis, organ-on chip) and environment (water control). Partners jointly have the production lines onto which the project’s innovation will be readily integrated, helping microfluidics to become a major component of the 4th industrial revolution.

The digitalization of industry opens the path for mass customization but requires leveraging the existing manufacturing ecosystems and establishing a collaborative manufacturing environment. DIMOFAC project will enable the modularity, adaptability and responsiveness of a production line by the integration of Plug-and-Produce modules in a Closed-Loop Lifecycle Management System, for continuous production adaptation, optimization and improvement, in a fast and flexible manner. Reconfigurability is achieved by implementing a Digital Twin of each module and by deploying Digital Thread linking product and process dataflow, enabling seamless secure communication throughout the product lifecycle in factory and connecting it to the management systems in conformance to RAMI4.0. The DIMOFAC consortium is issued from the leading European open initiatives on smart manufacturing, leveraging know-how from past and running EU projects such as INTEGRADDE, COMMUNION, HIMALAIA, BRAINPORT, iM²AM, MIDIH, MARKET 4.0 and building upon a pre-existing network of open DIHs and competence centers such as SMART FACTORY KL, PICTIC, FFLOR, AFH, MANUHUB@WG. Partners will further extend their services and networks to leverage on the increased flexibility brought by modular production systems. Six industrial pilot lines, with multi-material manufacturing, additive manufacturing and assembly capabilities, will enable to demonstrate DIMOFAC Modular Factory Solution, with reconfiguration time reduction of production lines, up to 75% expected for interactive displays (SCHALTAG), 50% for cosmetic, aeronautic and additive manufacturing (ALBEA, EIRE COMPOSITES and SCULPTEO); 30% for shavers (PHILIPS) and industrial modules (VDL). A key result will be the network of open pilot lines, offering R&T and services supporting process validation and implementation in EU SMEs, Midcaps and large organisations in different sectors, spreading knowledge, awareness and adoption of DIMOFAC Modular Factory Solution.