Festo solutions for next-generation laboratory automation

Modern laboratories face increasing demands for precision, speed, and repeatability — whether in diagnostics, pharmaceuticals, biotechnology, or research. Festo, with decades of experience in motion control and mechatronics, has developed a specialized set of solutions for laboratory automation included in the company’s LifeTech portfolio.

Festo LifeTech focuses on medical technologies and laboratory automation, offering both standard components and customized subsystem solutions. These are developed in collaboration with customers already at the project planning stage to reach an appropriate and practically implementable solution faster.

Table of Contents

• Portal systems for precise multi-axis motion
• Rotary gripper modules and parallel grippers for sample processing
• Rotary actuators – motion where it matters
• Liquid dosing and pipetting systems
• Miniaturization and integrated solutions for IVD applications
• Engineering collaboration and faster time to market
• Significance of the Festo LifeTech portfolio in next-generation laboratory automation

Portal systems for precise multi-axis motion

One of the most important requirements in laboratory automation is reliable and precise sample movement — horizontally, vertically, and along multiple axes simultaneously. Festo portal systems are designed exactly for this purpose, providing precise motion within the compact workspace typical of benchtop laboratory equipment.

Depending on application complexity, there are two main portal solutions available:

• Three-dimensional EXCL portal provides motion in the X-Y-Z directions and can be configured with two independently movable Z-axes. This allows multiple tools, such as pipetting heads or grippers, to operate simultaneously within one workspace, increasing throughput and reducing the need for separate devices.
• Flat EXCM portal provides compact X-Y motion for applications not requiring a third axis.

Both systems can be integrated with Festo linear actuators, motion controllers, and grippers to form complete automated work cells.

For example, in a sample processing system, a portal can move a microtiter plate from the loading position to a pipetting station and onward to an analysis device — without manual intervention. The system is maintenance-free, tested, and documented, facilitating validation processes in regulated industries.

Rotary gripper modules and parallel grippers for sample processing

Precise handling of sample containers — such as vials, tubes, and microtiter plates — is one of the main tasks in laboratory automation. Festo has developed specialized gripper modules that combine multiple functions in one compact tool, reducing system complexity and improving cycle times.

The EHMD rotary gripper module performs two tasks simultaneously — gripping and rotating. It is suitable for vial cap removal and placement, as well as for positioning and orienting small components.

The model with Z-compensation can automatically adapt to the thread pitch. This means there is no need to move the Z-axis during cap removal, thereby speeding up the process and reducing reconfiguration time. EHMD is suitable for a wide range of vial sizes and cap types, making it a flexible solution for various laboratory environments.

For tasks requiring only linear gripping without rotation, the following are suitable:

• EHPS parallel grippers
• EHAA-G1 gripper fingers with DHAS-GG inserts

These solutions provide consistent gripping force and repeatable motion for fragile or precise parts, such as microtiter plates or other non-standard laboratory containers.

Integration with portal systems enables the creation of compact automation cells capable of processing, inspecting, and orienting samples within a single workflow.

Rotary actuators – motion where it matters

Rotary actuators, such as the Festo ERMO series, provide controlled and precise angular motion in automation tasks requiring repeatable rotation. As a compact electromechanical drive with integrated motor and gearbox, it can complement portal systems and gripper modules in laboratory equipment.

ERMO is suitable for applications requiring sample orientation, positioning, or rotation as part of processing sequences, such as cap removal and placement. Combined with other motion and gripping components, it helps simplify kinematics and create more compact, clearer automation workflows.

Liquid dosing and pipetting systems

Precise liquid handling is essential in almost every laboratory automation application — from IVD diagnostics to pharmaceutical research. Inaccuracies in dosing or contamination between samples can affect analysis results and increase costs.

Festo offers integrated liquid handling solutions covering both dosing with dosing heads and open-loop pipetting systems.

• Dosing solutions rely on pressure and vacuum supply, such as the PGVA-1, dosing heads VTOE and VTOI, and valve control modules VAEM. These components together ensure precise liquid distribution in microtiter plates.
• Pipetting system with DHOE head is designed as an open system configurable according to specific requirements. It can include a medium-resistant head, disposable pipette tips, and automatic tip ejection using the DHAO-EJ.

This approach facilitates integration and helps avoid liquid contact with internal system parts, which is especially important when working with biological samples.

Accurate technical parameters, such as dosing volumes or pressure ranges, depend on the specific model and configuration, so they should be checked in datasheets or consulted with an engineer.

Miniaturization and integrated solutions for IVD applications

Point-of-care diagnostic devices impose high demands on compactness, reliability, and energy efficiency. Festo offers miniaturized components and integrated subsystems specifically developed for IVD equipment and lab-on-a-chip solutions.

Several approaches are used to reduce system size while increasing reliability:

• Diffusion Bonded Manifolds, manufactured using HADB technology from acrylic or ULTEM material, combine numerous channels into a single compact block without resin or glue. This helps avoid dead volumes and reduces leakage risk.
• Autonomous pressure and vacuum generation modules with built-in compressor, filtration, reservoirs, and pressure sensors provide a complete, integrated solution for small, self-sufficient diagnostic devices.
• Piezo technology proportional valves allow precise regulation of gases and liquids. Their advantages include quiet operation, compact size, and low power consumption, as energy is only required to change the flow state, not to maintain it.

Such manifolds can incorporate hundreds of components under one article number, simplifying assembly and documentation.

Engineering collaboration and faster time to market

The best components alone do not provide value if not properly integrated into a system. Festo plays a key role in engineering collaboration within laboratory automation — co-designing with customers from the concept stage to ensure the final solution meets specific technical requirements, available space, and budget.

Practical benefits for equipment manufacturers and system integrators:

• Reduced development time — using proven standard components from the prototype stage enables faster progression to serial production.
• Lower system complexity — integrated subsystems with a single article number simplify procurement, assembly, and documentation.
• Validation support — working in an ISO 13485 certified quality environment facilitates compliance processes in regulated industries, such as medical devices and IVD diagnostics.
• Global support — Festo’s engineering network provides assistance during design, installation, commissioning, and service.
• Modular scalability — systems can start with a basic configuration and later be expanded with additional axes, grippers, or fluid handling modules without redesigning the entire architecture.

Festo Technical Engineering Center (TEC) near Boston, USA, is a specialized life sciences research and development center with experts in gas and fluid control and sample processing. It is available to customers requiring in-depth engineering collaboration from the start of their projects.

Significance of the Festo LifeTech portfolio in next-generation laboratory automation

From modular components to complete automation systems — the Festo LifeTech portfolio enables laboratory equipment manufacturers and system integrators to create solutions combining precision, compactness, and reliability.

Portal systems, rotary gripper modules, liquid dosing solutions, and integrated manifolds together form the technological foundation for next-generation laboratory automation — whether designing a compact benchtop analyzer or a high-throughput screening station.

If you are designing a laboratory automation system or want to identify which Festo solutions best fit your application, contact ZTF Lāsma specialists. Our engineers will help select the most suitable components, discuss integration possibilities, and find the optimal path from concept to finished system.