Common Issues and Troubleshooting Tips

Common Issues with Modular Device Assembly

1. Protective mask on component 1 and/or component 2 comes off in two layers. You will remove the blue but will see a remaining clear layer. Remove this clear layer before assembly.
   

   A. The blue protective liner should come off as one layer, leaving behind component 2, with the PSA exposed. B. Occasionally, the protective liner comes off as two layers. Remove both to expose component 2 PSA. If you do not remove this layer, you will see that it does not bond to component 1.

2. The chip breaks during adhesion to component 1. The most common cause is the chip is not fully flat on fixture A1 pedestal. Sometimes it looks flat but is tilted by closer inspection. Look carefully directly from each side (see below). Tap sides with tweezers to be sure it is flat prior to adding component 1.
3. Component 1 fits tightly in fixture A1 and does not go down straight. This causes the chip to hit the PSA early and often off center. Either carefully remove the chip with tweezers and replace on the pedestal if it is very off center, or if it hit the PSA but is centered well, push gently down on the side with tweezers then place component 1 and the chip back on the fixture. Be sure the chip is not sitting on the lips of the pedestal. Then confirm good adhesion with fixture A2. If the PSA stretches or the chip breaks during the process, toss. One way to avoid this is to test component 1 on fixture A1 before adding the chip onto the pedestal to make sure it fits.
4. Dust particles from protective masks get in devices and cause bubbles. If you see particulates on the protective layers of the components, spray with EtOH before removing mask. If you see still particulates on the component after removing the protective layers, wet a Kimwipe with EtOH and wipe non-PSA layers to remove.
5. Port is a tight fit for pipette on component 1. This is less common but happens on occasion. Try pipetting on the other side. If both ports are too small, do not use component.
6. Channel is not centered on component 2. This is uncommon but happens on occasion and is more common on the strip edge components due to bowing of the strip during manufacturing. While we inspect components before shipping, it is good to do your own inspection prior to device assembly. If the channel is very off center, do not use the component.
7. PSA on component 1 comes off either with protective layer (prior to assembly) or with component 2 removal (after assembly, for analysis). This is also uncommon but has been seen on a handful of occasions. It is unclear if it is a defect in the PSA adhesion to the acrylic of component 1 or user error.