Laser Swab Cutting With Vision Alignment and Contamination Control

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Solution Overview

Problem

Current methods for cutting swabs to process biological and chemical samples are time-consuming, labor-intensive, prone to human error, and risk cross-contamination, leading to potential misidentification of samples.

Innovation Solution

A high-throughput swab processing system utilizing a cutting laser and swab sleeve with a seal, exhaust for particulate evacuation, and a carrier block with transparent imager for precise swab positioning, along with a vacuum manifold and robotic movement for automated swab cutting and deposition into wells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual cutting with scalpel is used, then device complexity is low, but productivity is low and reliability is poor due to human error

Engineering Contradiction:

Improveswab processing throughputVSAvoidsystem structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical cutting with a laser-based cutting system. The laser automatically cuts swab tips according to pre-programmed positions, eliminating the need for manual scalpel operation. This substitution dramatically increases throughput while maintaining simplicity through automated control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses vision guidance to automatically locate and cut swab tips without human intervention. The laser system self-regulates cutting depth and position based on real-time imaging, enabling autonomous operation that boosts productivity without requiring complex manual control mechanisms.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual cutting is used, then device complexity is low, but reliability deteriorates due to cross-contamination and misidentification risks

Engineering Contradiction:

Improvesample identification accuracyVSAvoidautomation system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a vision system as an intermediary between the operator and the cutting process. The imaging system captures swab positions, and automated software determines precise cutting locations, eliminating direct human contact with samples. This intermediary layer prevents cross-contamination while maintaining system simplicity through software-based control.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical cutting process is replaced with an automated laser system guided by vision technology. This substitution eliminates human error in sample handling and identification, significantly improving reliability. The automated system maintains simplicity by using standard laser and imaging components controlled through software.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated laser cutting is implemented, then productivity increases, but use of energy increases due to laser operation

Engineering Contradiction:

Improveprocessing speedVSAvoidlaser energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The laser operates in periodic pulses rather than continuously, activating only when a swab tip needs cutting. The system cycles through imaging, positioning, and cutting operations, with the laser firing briefly at each cutting point. This periodic operation maintains high throughput while significantly reducing overall energy consumption compared to continuous laser operation.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The laser applies energy only to the specific portion of each swab that needs cutting, rather than heating the entire swab or surrounding area. The cutting depth and laser duration are optimized to provide just enough energy for clean cuts, minimizing wasted energy while maintaining high processing speed through efficient energy delivery.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system significantly reduces human error, minimizes cross-contamination, and increases processing efficiency, allowing for accurate and rapid swab processing with enhanced reproducibility and safety.

Implementation Method 1

a cutting laser configured to emit a light beam

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

the swab is exposed to the light beam of the cutting laser when the cutter laser emits the light beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

an exhaust configured to evacuate particulate matter from the swab sleeve

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 4

an exhaust configured to evacuate particulate matter from the swab sleeve

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS20250319545A1Rapid automated swab cutting laser systems and method

Publication Date: 2025.10.16 GEORGIA TECH RES CORP

AI summary

An exemplary embodiment of the present disclosure provides a system for processing swabs. The system can include a cutting laser configured to emit a light beam and a swab sleeve. Swab sleeve can include a hollow body configured to house a swab, an aperture disposed on the hollow body in a position, such that when the swab is positioned proximate the aperture, the swab is exposed to the light beam of the cutting laser when the cutter laser emits the light beam. Swab sleeve can further include a seal configured to hold the swab in the swab sleeve.