ACE GIKEN Atom Ace 100 High-Pressure Viscous Fluid Dispensing System

Overview

The ACE GIKEN Atom Ace 100 High-Pressure Viscous Fluid Dispensing System is an engineered solution for precise, repeatable metering and deposition of non-Newtonian, high-viscosity fluids under controlled pressure conditions. Designed around a positive-displacement pressurized reservoir principle, the system utilizes regulated nitrogen or compressed air to drive material from sealed containers—including 1 kg and 3 kg cans, cartridges, and drums—through a high-integrity fluid path constructed entirely of SUS314 stainless steel. This architecture eliminates intermediate transfer steps, mitigating contamination risk and preserving material integrity during dispensing. Unlike peristaltic or auger-based systems, the Atom Ace 100 applies uniform hydrostatic pressure across the entire fluid column, enabling stable flow rates even with viscosities exceeding 1,000,000 mPa·s (e.g., silicone gels, epoxy pastes, and grease formulations). Its vacuum-compatible construction supports pre-sterilization protocols in accordance with ISO 13485-aligned cleanroom workflows, making it suitable for applications where bioburden control and material sterility are prerequisites.

Key Features

• SUS314 stainless steel wetted components ensure chemical resistance, corrosion durability, and compatibility with autoclave and vacuum sterilization cycles
• Direct-can dispensing capability eliminates manual decanting, reducing operator exposure and cross-contamination risk
• Modular integration with DPC-800C and DPC-800CDX programmable controllers for time-, pressure-, and stroke-based dispensing logic
• BP-109 series high-pressure Balpet valves provide rapid, low-hysteresis on/off actuation with rated service pressure up to 10 MPa
• Configurable mounting kit (base, vertical rod, nozzle holder) enables rigid alignment in benchtop, robotic arm-mounted, or inline process configurations
• Dual-diameter polyurethane tubing set (φ4×φ2.5 mm and φ6×φ4 mm) and G1/4 nylon high-pressure hose support flexible routing and pressure-rated delivery over extended distances
• 20-piece metal nozzle set with interchangeable orifice geometries facilitates optimization for bead width, aspect ratio, and surface wetting behavior

Sample Compatibility & Compliance

The Atom Ace 100 is validated for use with shear-thickening and shear-thinning viscous media commonly encountered in biofabrication, diagnostics reagent manufacturing, and medical device assembly—including silicone elastomers (e.g., Dow Corning® SILASTIC™), two-part epoxies (e.g., MasterBond EP21LV), and pharmaceutical-grade greases (e.g., Dow Corning® 111). All contact surfaces comply with USP Class VI biological safety requirements. The vacuum-capable housing design permits in-situ sterilization prior to aseptic filling operations, supporting compliance with ISO 14644-1 Class 5–7 cleanroom environments. While not inherently GLP/GMP-certified as a standalone unit, its deterministic pressure control architecture and traceable controller logging (via DPC-800CDX audit trail functionality) facilitate integration into FDA 21 CFR Part 11-compliant manufacturing execution systems when paired with validated software interfaces.

Software & Data Management

The DPC-800C and DPC-800CDX controllers offer dual-channel analog/digital I/O, real-time pressure monitoring, and programmable dispensing profiles stored in non-volatile memory. The DPC-800CDX variant includes RS-485 Modbus RTU communication, enabling bidirectional data exchange with PLCs or SCADA platforms for batch record generation and electronic signature capture. All dispense events—including start/stop timestamps, applied pressure setpoints, and valve actuation duration—are logged with millisecond resolution. Optional footswitch input allows hands-free operation during manual station setups, while configurable alarm thresholds trigger visual and relay outputs upon pressure deviation or timeout conditions—supporting preventive maintenance scheduling and process deviation detection.

Applications

• Precision dispensing of hydrogel precursors in 3D bioprinting scaffolds and microfluidic chip priming
• Controlled deposition of encapsulation compounds onto diagnostic biosensor arrays and lateral flow test strips
• Automated application of medical-grade adhesives during implantable device assembly (e.g., pacemaker housings, neurostimulator casings)
• Consistent metering of silicone sealants in sterile barrier packaging validation studies
• High-fidelity dispensing of conductive pastes in flexible electrode fabrication for wearable biosensors

FAQ

Can the Atom Ace 100 be used with shear-sensitive biomaterials such as collagen or alginate solutions?

Yes—when operated at low pressure gradients and optimized dwell times, the system minimizes shear history through laminar, pressure-driven extrusion rather than mechanical agitation.
Is the DPC-800CDX controller compliant with FDA 21 CFR Part 11 for electronic records?

The controller supports audit trail logging and user access levels; full Part 11 compliance requires site-specific validation of the complete software environment and network configuration.
What is the maximum recommended operating pressure for continuous dispensing?

The BP-109 valve and SUS314 manifold are rated for sustained operation up to 7 MPa; intermittent peaks up to 10 MPa are permissible per manufacturer specifications.
Does the system support ISO-standard Luer or DIN 13827 nozzle interfaces?

Standard nozzles use M3 or M4 threaded mounts; custom adapters for Luer-lock or DIN interfaces are available upon request.
How is vacuum sterilization performed without compromising seal integrity?

The system employs double-O-ring static seals with FKM elastomers and vacuum-rated stainless steel flanges, verified to hold ≤10⁻² mbar for ≥30 minutes per JIS B 8605-1 test protocol.