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Liquid Handling · Automated pipetting · Automation · Imaging integration · 2025 · Applied Intelligence

Real-time AI-driven quality control for laboratory automation: a novel computer vision solution for the opentrons OT-2 liquid handling robot

Abstract The adoption of robotics and automated solutions in life sciences R&D has accelerated in recent years, driven by the need to process increasing sample volumes, protect laboratory staff from hazardous substances, and manage financial pressures. Various automation systems, each with distinct levels of sample processing, transportation tasks, and data management, are available to meet specific application requirements, with liquid handling robots taking pivotal positions in these systems.

Performance the paper reports

0 of 5
  1. Motion—Motion accuracy: not reported
  2. Volume—Volumetric accuracy: not reported
  3. Viability—Cell viability: not reported
  4. Unattended—Unattended operation: not reported
  5. Standard—Standard compliance: not reported

The full text was read and states no figure for any of the five.

How hard this is to adopt

3.1 of 5, higher is easier

Each score is shown against the range the other 59 builds actually occupy, because no criterion uses the full 1–5 scale. These describe how reproducible the build is, not how good the science is.

  • Resolution

    3/1–5

    Vision volume estimation validated only over 50-270 uL (3.4% mean error, 95% accuracy) with P20 tips imaged at 10/20 uL; sub-10 uL capability is the host OT-2 and unmeasured.

  • Throughput

    5/2–5

    Host OT-2 8-channel arm imaged with all eight tips and mapped across a 12x8 96-well plate, a parallel multi-tip head, though channels are not independently controlled.

  • Parts sourcing

    3/2–4

    Part sourcing complexity not explicit; assigned moderate default.

  • Skill needed

    2/2–4

    Multiple advanced technical skills appear required.

  • Facilities needed

    3/2–4

    Requires accessible but nontrivial lab/maker equipment.

  • Documentation

    3/2–5

    Some open documentation or files are available.

  • Validation effort

    3/2–4

    50 live runs, 100 volume tests, mAP@50 of 0.995, 98% missing-tip accuracy and regression calibration, but Table 5 compares only to a prior YOLOv5 paper, not a conventional or manual benchmark.

  • Cycle time

    3/1–4

    Only 1.1 s/frame versus 8 s for the prior AI method; no timing comparison reported against manual pipetting or a commercial handler, and vision adds per-step overhead.

2 further criteria are recorded but not shown
  • Application Level — scored 4 (75% of records share one value), so it cannot separate one build from another.
  • Build Time (scored for only 6 of 60 records), so it cannot separate one build from another.

Both remain in the published dataset.

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Matched by doi · retrieved 2026-07-21

Abstract

Abstract The adoption of robotics and automated solutions in life sciences R&D has accelerated in recent years, driven by the need to process increasing sample volumes, protect laboratory staff from hazardous substances, and manage financial pressures. Various automation systems, each with distinct levels of sample processing, transportation tasks, and data management, are available to meet specific application requirements, with liquid handling robots taking pivotal positions in these systems. However, current liquid handling robots, such as the Opentrons OT-2, lack integrated vision-based quality control, which limits their accuracy and reliability. This study presents an AI-driven computer vision model designed to enhance quality control in laboratory automation. By integrating the YOLOv8 object detection model with the OT-2, our model enables precise detection of pipette tips and liquid volumes, providing real-time feedback on errors, such as missing tips and incorrect liquid levels. Our results demonstrate the model's effectiveness and accessibility, presenting an affordable solution for improving automation in academic and research laboratories. This closed-loop system transforms the OT-2 into a robust tool for automated laboratory tasks, making it an accessible and cost-effective approach for enhancing quality control in laboratory automation and addressing a critical gap in available tools for resource-limited settings.

Bibliographic details

Published
2025-03-10
Journal/source
Applied Intelligence
Publisher
Springer Science and Business Media LLC
DOI
10.1007/s10489-025-06334-3
Type
journal-article
Language
en
Volume / issue
55 / 7
Pages
Not supplied
ISSN
0924-669X, 1573-7497

Access and metrics

Open access
Yes
OA status
hybrid
License
cc-by
Version
publishedVersion
Cited by
8
References
18
Retracted
No

Authors and affiliations

  1. Sana Ullah KhanTechnical University of Denmark
  2. Vilhelm Krarup MøllerTechnical University of Denmark
  3. Rasmus John Normand FrandsenTechnical University of Denmark
  4. Marjan MansourvarCorresponding authorTechnical University of Denmark

Topics and keywords

Industrial Vision Systems and Defect DetectionFault Detection and Control SystemsImage Processing Techniques and ApplicationsComputer scienceAutomationRobotHuman–computer interactionQuality (philosophy)Control (management)Laboratory automationComputer visionArtificial intelligenceSimulationMechanical engineering

Funding

  • Technical University of Denmark
Perspective and practical signals

Why it matters

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Limitations

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