Sample compact benchtop system
144
0
Real-time tracking points via time-of-flight cameras
700+
0
Annual test capacity within a single scalable system
60,000+
0
Case Study
Automating Liquid-Based Cytology Sample Preparation at Diagnostic Scale
From Manual Workflows to Fully Integrated Pre-Analytical Automation
A global diagnostics company sought to eliminate manual, error-prone sample preparation from its liquid-based cytology workflow for STI and HPV testing without compromising throughput, accuracy, or laboratory compatibility. Ascential delivered a 144-sample automated benchtop platform with real-time sample control and seamless integration into existing molecular diagnostics infrastructure.
The Challenge
Liquid-based cytology testing for STIs and HPV is a high-volume, precision-sensitive process performed across core laboratories, hospitals, and reference lab environments. Traditionally, sample preparation has relied on manual aliquoting, a workflow that is not only time-consuming but also introduces risk of human error and repetitive strain injury for laboratory staff.
The client needed to develop a next-generation automated pre-analytical system capable of handling liquid-based cytology specimens at scale. Their goals were clear: achieve high-throughput capacity of 60,000 or more tests per year, reduce manual handling throughout the workflow, and ensure the system could operate within the spatial and operational constraints of existing laboratory environments.
Eliminate Manual Sample Preparation
Replace time-consuming, error-prone manual workflows that increased repetitive strain injury risk for laboratory personnel.
Achieve High-Volume Capacity
Design a system capable of processing 60,000+ tests per year within a compact, scalable benchtop footprint.
Fit Seamlessly Into Existing Lab Infrastructure
Ensure compatibility with molecular diagnostics platforms and pre-existing laboratory environments without major facility modifications.
Improve Sample Integrity and Control
Deliver real-time sample tracking and precision handling to reduce errors across liquid-based cytology specimen preparation.
Ascential's Solution
Rather than addressing individual pain points in isolation, Ascential’s cross-functional engineering team, spanning mechanical, fluidic, optical, software, and systems disciplines, designed and built a fully integrated automated platform from the ground up. The result is a compact, continuous-access pre-analytical system that automates the processing of liquid-based cytology samples end-to-end.
By engaging early and owning the full development lifecycle, Ascential was able to engineer for performance, regulatory alignment, and laboratory usability from the outset — reducing the risk of costly late-stage redesigns and keeping the program on schedule.
The platform integrates seven time-of-flight cameras that continuously track more than 700 sample points, providing real-time sample control and immediate error detection throughout the workflow. Precision thermal and fluidic management systems maintain sample integrity at every stage, while automated labeling with Code 128 barcoding ensures full chain-of-custody traceability from intake through processing.
Using a 144-sample benchtop footprint for core, hospital, and reference laboratory environments, the system reduces manual touchpoints, mitigates repetitive strain injury risk for lab personnel, and integrates seamlessly with existing molecular diagnostics platforms.
Technical Capabilities Delivered
The system integrates a sophisticated combination of subsystems, all designed, validated, and documented in-house by Ascential’s engineering team:
| Capability | What Ascential Built |
|---|---|
| Robotics & Motion Control | End-to-end automated workflow with robotic sample handling to reduce manual touchpoints and repetitive strain injury risk |
| Vision & Sensing | 7 time-of-flight cameras tracking 700+ points for continuous real-time sample control and error detection |
| Fluidic Handling | Precision fluidic management systems for accurate aliquoting of liquid-based cytology specimens |
| Thermal Management | Integrated thermal control to maintain sample integrity throughout the processing workflow |
| Sample Identification | Automated labeling with Code 128 barcoding for complete chain-of-custody traceability |
| System Architecture | 144-sample benchtop form factor designed for core, hospital, and reference laboratory environments |
| Software & Controls | Coordinated system control software managing multi-subsystem integration across the full automated workflow |
Key Results
Ascential delivered a high-throughput diagnostic instrument that fundamentally transformed sample preparation operations for the client. The completed system exceeded performance targets across every key dimension:
- Real-time sample control across 700+ tracking points, enabled by a 7-camera time-of-flight vision system integrated throughout the automated workflow.
- 60,000+ annual test capacity within a 144-sample compact benchtop form factor suitable for core, hospital, and reference labs.
- End-to-end automation of liquid-based cytology sample preparation, substantially reducing manual handling and eliminating repetitive strain injury risk for laboratory staff.
- Seamless integration with existing molecular diagnostics platforms and downstream workflows, optimizing overall lab operations and improving throughput and productivity.
- Precision fluidic and thermal management with automated Code 128 barcoding, delivering full sample traceability and integrity across the complete workflow.
Why It Matters
Sexually transmitted infections and HPV-related disease affect millions of patients globally. The speed, accuracy, and reliability of diagnostic testing directly influences clinical outcomes, treatment timelines, and public health response. When laboratory workflows are burdened by manual processes, the risks extend beyond operational inefficiency, they affect patient care.
By automating the pre-analytical phase of liquid-based cytology testing, this platform enables laboratories to operate at higher volumes with greater consistency, fewer errors, and reduced burden on staff. For the client, it represents a commercially scalable platform that brings meaningful operational and clinical value to market. For laboratories deploying the system, it means faster, more reliable sample processing when diagnostic accuracy matters most.
Ascential’s role extended well beyond mechanical and software engineering. By owning the full development lifecycle, from concept through production-ready instrumentation, the team was able to integrate design controls, manufacturing process development, and system validation in parallel, compressing timelines and reducing the fragmentation that typically slows complex diagnostic device programs.
Your Life-Saving Product Requires Precision Manufacturing
Curious about how quickly Ascential can scale your complex development and production workflows? Let’s solve your biggest design, automation, or manufacturing challenge.
Get Your 15-Minute Consultation