Why generate a BOM instead of buying a vendor kit?

Vendor kits lock you into one fitting catalog and one chip format. A custom BOM lets you mix the cheapest tubing, the smallest-dead-volume connectors, and the right reservoir size for your sample. For a 4-channel rig the difference is often $200+ per setup.

How is system dead volume estimated?

Dead volume = (tubing volume per channel × number of channels) + (per-connector dead volume × number of ports). Tubing volume comes from π(ID/2)² × length. Connector defaults are vendor-neutral published values from Idex, Cole-Parmer, and Darwin Microfluidics.

Why does the tool warn about tubing ID > OD bore?

Tubing OD is the outside diameter — it must fit inside your fittings. Tubing ID is what carries fluid. ID has to be smaller than the wall-to-wall bore of the tubing itself. 1/16" OD tubing maxes out around 1.0 mm ID; 1/32" OD around 0.5 mm ID. If you ask for an ID larger than the bore, the BOM is physically impossible.

Should I always order quick-disconnect couplers?

Only if you swap chips frequently or run multi-protocol experiments back-to-back. Quick-disconnects add ~3–8 μL of dead volume per pair and roughly $15 per pair. For a single dedicated rig they are wasted money; for shared/educational rigs they save real time.

Are the connector dead volumes accurate for my hardware?

The defaults (Luer $\approx$ 5 μL, Mini-Luer $\approx$ 2 μL, threaded ferrule $\approx$ 0.5 μL, press-fit $\approx$ 1 μL) are typical published values. Vendor-specific connectors can differ — always check your fitting datasheet for critical work. The tool is designed for first-pass sizing, not final reagent budgeting.

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No. All math runs in your browser. No values are sent to any server.

ToolsConductScience tool

MicrofluidicsFree in-browser calculator

Microfluidic Interface & Connector BOM Generator.

Wizard for chip-side connectors, instrument-side fittings, tubing, plugs, syringes, and reservoirs. Outputs a printable bill of materials and a system dead volume estimate. Free. Client-side.

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Validated2026-04-07

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Load example microfluidic interface BOM generator data to see the full workflow

Chip & Ports

Chip format

Inlets

Outlets

Unused chip ports (need plugs)

Tubing & Connectors

Tubing OD

Tubing ID (mm)

Tubing length per channel (cm)

Connector style

Instrument

Drive type

Quick-disconnect couplers required

Reservoirs

Include reservoirs / sample vials

Reservoir volume (mL each)

⚠️ No plugs ordered. If your chip has unused inlets/outlets you must plug them — set the unused-ports field above.

Bill of Materials

Item	Qty	Unit	Notes
Chip-side Luer connector	3	pcs	One per inlet + outlet (2 in / 1 out)
Instrument-side fitting (Luer-tipped syringe)	3	pcs	Match to 1/16" OD tubing
Tubing (1/16" OD)	0.9	m	30 cm × 3 channels
Syringe (size to reservoir + dead volume)	2	pcs	One per inlet channel
Reservoir / sample vial	2	pcs	5 mL each

Total tubing

0.90 m

System dead volume

467.39 μL

When to use

Speccing a new microfluidic rig before placing the supply order
Building a printable shopping list for a new lab member
Documenting the plumbing of a published experiment in supplementary methods
Comparing two interface designs (Luer vs threaded ferrule) by dead volume
Generating a teaching reference for connector / tubing / fitting matching

Do not use for

For pressure manifolds with non-standard fittings (consult vendor catalog)
For valved chip arrays with internal manifolds (vendor BOM only)
For gas-phase systems
For hand-built custom fittings (machined adapters, glued joints)

Always plug unused ports

Microfluidic chips often ship with extra inlets. Leaving them open lets air in and ruins flow. Always order one plug per unused port.

Match instrument-side fitting to your pump

Syringe pumps want Luer-tip syringes. Pressure controllers want manifold fittings. Peristaltic pumps want soft tubing in the pump head + a rigid jumper to the chip. Mismatches mean wasted parts and leaks.

Tubing ID drives dead volume more than length

A 30 cm run of 1.0 mm ID tubing has ~235 μL of fluid — more than most chips. Drop to 0.5 mm ID and the same 30 cm holds 59 μL. The single biggest BOM lever is ID, not length.

Order ferrules in pairs

Threaded ferrule fittings need a ferrule + a nut. Some vendors ship them as a pair, some separately. Always double-check before placing the order or you will be stuck with half a fitting.

Method

Chip-side connectors = inlets + outlets. Instrument-side fittings = inlets + outlets. Tubing length = (lengthCm $\times$ channels) / 100 m. Plugs = unused ports. Syringes = inlets (syringe-pump only). Reservoirs = inlets (when requested). System dead volume = ports $\times$ tubing volume per channel + ports $\times$ per-connector dead volume. Tubing volume from π(ID/2)² $\times$ length, 1 $\text{mm}^{3}$ = 1 μL. Connector defaults from Idex/Cole-Parmer/Darwin Microfluidics published tables.

Validated

Last validated 2026-04-07. Calculations are designed for planning and documentation support; verify procurement decisions against manufacturer specifications or institutional SOPs.

How to cite

How to Cite

ConductScience Microfluidic Interface & Connector BOM Generator (v1.11.0). ConductScience, Inc. 2026. Available at: https://conductscience.com/tools/microfluidic-interface-bom-generator

Why a BOM Beats a Shopping List

A scribbled shopping list — "5 Luers, some tubing, two syringes" — is how labs end up with mismatched OD/ID, missing plugs for unused ports, and three trips to the supply room. A real BOM forces you to count every part *and* its mating part: every chip-side connector has an instrument-side fitting, every tubing run has the right OD for the connector, every unused port has a plug.

The 30 minutes you spend generating a clean BOM saves a half day of "the experiment is delayed because we are waiting on a $4 ferrule." It also makes the rig reproducible — anyone can rebuild it from the BOM card, no tribal knowledge required.

Tubing OD vs ID: A Two-Sentence Explainer

OD (outer diameter) has to match your fitting. 1/16" Luer fittings only accept 1/16" OD tubing. 1/32" fittings only accept 1/32" OD tubing.

ID (inner diameter) controls flow rate, backpressure, and dead volume. For a given OD you can pick from a small range of IDs — thicker walls give smaller ID and more pressure tolerance; thinner walls give larger ID and lower backpressure. Always confirm ID is less than the bore of your OD class.

Luer vs Mini-Luer vs Threaded Ferrule vs Press-Fit

Luer (≈ 5 μL): the universal default. Cheap, fast to swap, fits everything. Use when dead volume is not the limit.

Mini-Luer (≈ 2 μL): same workflow as Luer but with smaller bore. Drops connector dead volume ~60%. Use for precious-sample work.

Threaded ferrule (≈ 0.5 μL): nut + ferrule + tubing pressed into a flat-bottom port. Smallest dead volume of the four, highest pressure tolerance, slowest to swap. Use for high-pressure (> 5 bar) or single-cell work.

Press-fit (≈ 1 μL): tubing pushes directly into a chip-port boss. No nut. Common on commercial chips with built-in interconnects. Fast and clean but only works with the matching chip format.

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