Methods and systems to prevent punch loss during automated sample processing

1. An automated system for punching out pieces of a porous substrate for biological samples comprising,

a puncher;

an ejector pin having a cross-sectional dimension, a length and a distal end;

a porous substrate support with an opening larger the cross-sectional dimension of the ejector pin;

a plurality of sample piece receptacles, each of which has an opening; and

an automated handling subsystem that moves in x, y, and z directions and aligns an opening in one or more of the receptacles substantially flush with the opening in the support, wherein the sample piece receptacles are positioned below the porous substrate support whereby the ejector pin, the opening in the porous substrate support and the sample piece receptacles are all vertically aligned with each other in the z direction;

wherein the length of ejector pin is configured, together with the opening of sample piece receptacle, so that the distal end of the ejector pin, when in an actuated position, extends into the opening of the receptacle; and wherein one or more of the sample piece receptacles are seated on the handling subsystem and move in the x, y and z directions with the handling subsystem; and wherein the substrate support is in a fixed relationship with the handling subsystem and moves in the x, y and z directions with the handling subsystem.

2. The system of claim 1 , wherein the puncher has an inner cannular bore through which the ejector pin moves.

3. The system of claim 1 , wherein the puncher comprises a punching head and the porous substrate support comprises a die corresponding to the punching head.

4. The system of claim 3 , wherein the punching die has a cross-sectional dimension that corresponds to the cross-sectional dimension of the punching head.

5. The system of claim 1 , wherein one or more of the receptacles comprises a well on a multi-well plate.

6. The system of claim 5 , wherein the multi-well plate is seated on the handling subsystem.

7. The system of claim 5 , wherein the multi-well plate comprises at least ninety-six (96) wells.

8. The system of claim 1 , wherein one or more of the receptacles comprises a vial.

9. The system of claim 8 , wherein the vial is seated on the handling subsystem.

10. The system of claim 1 , wherein the sample receptacles comprise a plurality of cover flaps that comprise a thin film material having a low modulus and inherently high flexibility.

11. The system of claim 10 , wherein the cover flaps curve inward and form a low resistance opening in the cover.

12. The system of claim 11 , wherein the thin film material has a thickness that is about equal to or less than 100 um thick and comprises one or more of polyester, polypropylene, and polyester/polypropylene.

13. The system of claim 12 , wherein the thin film material has a thickness of about equal to or less than 65 um.

14. An automated method for punching out pieces of a porous substrate for biological samples comprising,

a. loading the porous substrate onto a support comprising a die and an opening;

b. moving a receptacle support, comprising a plurality of receptacles, configured to move in an x, y and z direction, in at least a z-direction to position one of the receptacles, each of which is configured to receive only one piece of substrate, relative to the support so that an opening in the receptacle is aligned and substantially flush with the opening in the support;

c. actuating a punching head so that the punching head passes through the die, thereby punching a piece out of the porous substrate;

d. actuating an ejector pin, having a distal end, to eject the punched piece directly from the die and into the receptacle aligned with the opening in the support whereby the distal end of the ejector pin extends past the opening to deposit the punched piece into an interior of the receptacle; and

e. automatically repeating at least steps b through d, as needed.

15. The automated method of claim 14 , wherein the punched piece comprises a portion of the biological sample.

16. The method of claim 15 , wherein one or more of the receptacles comprises a well on a multi-well plate.

17. The method of claim 16 , wherein the multi-well plate is seated on a handling subsystem that moves in x, y and z directions.

18. The method of claim 16 , wherein the multi-well plate comprises at least ninety-six (96) wells.

19. The method of claim 14 , wherein one or more of the receptacles are seated on a handling subsystem and move in the x, y and z directions with the handling subsystem.

20. The method of claim 14 , wherein the substrate support is in a fixed relationship with the handling subsystem and moves in the x, y and z directions with the handling subsystem.

21. The method of claim 14 , wherein the punching head has an inner, cannular bore through which the ejector pin moves.

22. The method of claim 14 , wherein the die has a cross-sectional dimension that corresponds to a cross-sectional dimension of the punching head.

23. The method of claim 14 , wherein one or more of the receptacles comprises a vial.

24. The method of claim 23 , wherein the vial is seated on a handling subsystem that moves in x, y and z directions.

25. The method of claim 14 , wherein the sample receptacles comprise a plurality of cover flaps that comprise a thin film material having a low modulus and inherently high flexibility.

26. The method of claim 25 , wherein the cover flaps curve inward and form a low resistance opening in the cover.

27. The method of claim 26 , wherein the thin film material has a thickness that is about equal to or less than 100 um thick and comprises one or more of polyester, polypropylene, and polyester/polypropylene.

28. The method of claim 27 , wherein the thin film material has a thickness of about equal to or less than 65 um.