Objective. To develop an in-line microwave fluid warming system that e
liminates the difficulties of uneven heating that are characteristic o
f batch-mode microwave fluid warmers. Methods, Using a commercial micr
owave oven, we developed a method for warming fluid as it flowed throu
gh tubing along a defined path in the oven's cavity. Algorithms utiliz
ing either proportional or adaptive control were used to control micro
wave heating cycles by varying the heating pulsewidth during 3-second
epochs. Methods of fluid entry and exit were devised to minimize micro
wave leakage. Heating performance was tested using icewater at multipl
e flow rates from 18 mL/min to 105 mL/min. Results. In all warming tes
ts, the system achieved temperature control without exceeding the maxi
mum temperature allowable based on American Association of Blood Banks
requirements. The adaptive control maintained the set temperature, wi
th peak-to-peak oscillations of 2 degrees C or less. Microwave leakage
was below the commercially required limit for home microwave applianc
es. Conclusions, The combination of proportional and adaptive control
is successful in controlling the permanent magnet magnetron microwave
energy to heat the icewater tested. The in-line microwave warmer has t
he potential to become a successful medical fluid warmer. More study i
s needed to determine the stability of the control system under clinic
al conditions, and to evaluate its utility for warming blood.