A Novel Continuous-Flow PCR Microdevice Operated by a Single Heat Source

This paper presents a constant-temperature, single-heat-source continuous-flow PCR (CF-PCR) microdevice that achieves stable thermal control for denaturation, annealing, and extension on a single platform. Key innovations include: (1) a metal-powder/PDMS thermal conduction block with trapezoidal geometry that generates a programmable temperature gradient and tunable residence times under one heat source; and (2) a thermoelectric cooler (TEC)-based Peltier system that creates distinct high- and low-temperature zones by co-optimizing the hot/cold side temperature difference, spacer material (92% alumina), and input voltage (3.6 V). A self-pressurized gas-diffusion micropump, enabled by a capillary quartz tube at the outlet, drives continuous sample flow without external actuation. The platform features three configurations: an on-chip zoned-heating design, an off-chip coiled-tube setup, and a battery-powered handheld system (727 g, 6 W, ~4 h runtime). Using CNC-machined and thermally bonded PMMA microchips with BSA passivation, the on-chip device achieves ~80% amplification efficiency relative to commercial instruments for H7N9 and pGEM-3Zf(+); the off-chip version reaches ~75%. The portable system yields HPV and RUBV amplification intensities comparable to benchtop devices. This approach provides a practical, scalable solution for “sample-in–answer-out” nucleic acid testing in point-of-care settings.