Design and Development of a Dried Whole Blood Cartridge for Point-Of-Care Clinical Diagnosis

This paper presents the complete design and development of a dried whole blood cartridge designed for point-of-care (POC) clinical diagnostics. The system integrates a near-infrared (NIR) spectroscopy sensor with a disposable multilayer paper cartridge capable of collecting and analyzing small, controlled volumes of capillary blood (20 μL). The work emphasizes a technical and iterative design approach that combines product design with both additive and subtractive prototyping, supported by experimental validation. The development process involved multiple design iterations focusing on fluid transport, capillary dynamics, usability, and optical integration. Several materials and manufacturing processes, such as CNC (Computer Numerical Control) machining and Material Jetting (MJ), were explored to optimize channel geometry and flow behavior. Experimental results guided successive refinements, leading to a cartridge configuration that ensures efficient capillary action, minimal coagulation, and consistent optical alignment with the sensor’s analysis zone. The study underscores the importance of an integrated engineering approach that unites design methodology, material selection, and manufacturing processes to achieve a reliable and reproducible cartridge for point-of-care blood diagnostics. It demonstrates how iterative design, supported by experimenal testing, can effectively bridge the gap between experimental prototyping and practical implementation in medical device development.