Sparger device for a bioprocessing system and method of manufacturing a sparger device

A sparger device, comprising:

• at least one unitary sparge tube with a constant outside diameter defining a central passageway having a distal end, a plurality of sparge holes along a longitudinal extent of the sparge tube, and an inlet opening formed in the central passageway about the longitudinal extent of the sparge tube;
• a unitary hub coupled with the sparge tube while leaving the sparge tube intact, the hub having a central feed passageway in fluid communication with the central passageway of the sparge tube for providing gas to the sparge tube, wherein the central feed passageway has a larger diameter portion configured to fit a core pin and a smaller diameter portion with the smaller diameter substantially similar to that of the sparge tube central passageway, the larger diameter portion and the smaller diameter in fluid communication with the inlet opening in the sparge tube, wherein the smaller diameter portion is proximal to the inlet opening and the larger diameter portion is distal to the inlet opening, wherein the smaller diameter portion extends directly to the inlet opening without extending into the central passageway;
• and
• a cap on the distal end of the sparge tube, wherein the cap is a distinct and physical element that is separate from the sparge tube, and having a cap body formed of solid material with a recess having a uniform diameter throughout the cap body that corresponds in diameter with the constant outside diameter of the sparge tube to receive the distal end of the sparge tube therein and outward extending sidewalls defining the recess formed therebetween, each of the outward extending sidewalls advancing along an outer surface of the constant outside diameter of the sparge tube, the recess of the cap enclosing the distal end and the outward extending sidewalls enclosing a portion of the outer surface of the constant outside diameter of the sparge about the distal end, an outlet opening formed on an outer surface of the cap body, and a throughbore extending from the outlet opening directly through the cap body and to the distal end of the constant outside diameter of the sparge tube, wherein the throughbore is in fluid communication with the central passageway of the sparge tube, and wherein the outlet opening is formed on a part of the cap body that directly adjoins the distal end of the sparge tube.