Unitary biochip providing sample-in to results-out processing and methods of manufacture

A unitary, stationary biochip, which upon insertion into an electrophoresis instrument having pneumatic, thermal, high voltage and optical subsystems, and a process controller, generates a nucleic acid sequencing or sizing profile from at least one sample, said biochip comprising:

• a macrofluidic processing subassembly in connection with a fluidic subassembly and a pneumatic subassembly, comprising at least one chamber adapted to receive a sample;
• the fluidic subassembly, comprising a fluidic plate having a top and bottom patterned thermoplastic sheet bonded thereon, to form at least one fluid transport channel on each sides of the plate and an amplification chamber adapted to connecting to the thermal subsystem;
• the pneumatic subassembly which is adapted to connecting to the pneumatic subsystem of said instrument, and to the subassemblies of said biochip, comprising a pneumatic plate having a top patterned thermoplastic sheet bonded thereon, and one or a plurality of drive lines to pneumatically drive only air on instructions from said process controller;
• a valve subassembly, positioned between and connected to said fluidic and pneumatic subassemblies, configured to receive only air from said one or a plurality of drive lines and open or close at least one valve in response thereto, thereby driving air or fluids on or within said fluidic subassembly;
• and
• a separation and detection subassembly adapted for connecting to the high voltage and optical subsystems and process controller on said instrument, said separation and detection subassembly comprising at least one separation channel, and further comprising a detection region positioned to send signals from each of said at least one separation channels to said optical subsystem on said instrument.