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We present the integration of a flow focusing microfluidic device in a dielectrophoretic application that based on a tapered aluminum microelectrode array (TAMA). The characterization and optimization method of microfluidic geometry performs the hydrodynamic flow focusing on the channel. The sample fluids are hydrodynamically focused into the region of interest (ROI) where the dielectrophoresis force (FDEP) is dominant. The device geometry is designed using 3D CAD software and fabricated using the micro-milling process combined with soft lithography using PDMS. The flow simulation is achieved using COMSOL Multiphysics 5.5 to study the effect of the flow rate ratio between the sample fluids (Q1) and the sheath fluids (Q2) toward the width of flow focusing. Five different flow rate ratios (Q1/Q2) are recorded in this experiment, which are 0.2, 0.4, 0.6, 0.8 and 1.0. The width of flow focusing is increased linearly with the flow rate ratio (Q1/Q2) for both the simulation and the experiment. At the highest flow rate ratio (Q1/Q2 = 1), the width of flow focusing is obtained at 638.66 µm and at the lowest flow rate ratio (Q1/Q2 = 0.2), the width of flow focusing is obtained at 226.03 µm. As a result, the flow focusing effect is able to reduce the dispersion of the particles in the microelectrode from 2000 µm to 226.03 µm toward the ROI. The significance of flow focusing on the separation of particles is studied using 10 and 1 µm polystyrene beads by applying a non-uniform electrical field to the TAMA at 10 VPP, 150 kHz. Ultimately, we are able to manipulate the trajectories of two different types of particles in the channel. For further validation, the focusing of 3.2 µm polystyrene beads within the dominant FDEP results in an enhanced manipulation efficiency from 20% to 80% in the ROI.

The synthesis of nanoparticles in microchannels promises the advantages of small size, uniform shape and narrow size distribution. However, only with insights into the mixing processes can the most suitable designs and operating conditions be systematically determined. Coaxial lamination mixers (CLM) built by 2-photon polymerization can operate long-term stable nanoparticle precipitation without fouling issues. Contact of the organic phase with the microchannel walls is prevented while mixing with the aqueous phase is intensified. A coaxial nozzle allows 3D hydrodynamic focusing followed by a sequence of stretch-and-fold units. By means of a digital twin based on computational fluid dynamics (CFD) and numerical evaluation of mixing progression, the influences of operation conditions are now studied in detail. As a measure for homogenization, the mixing index (MI) was extracted as a function of microchannel position for different operating parameters such as the total flow rate and the share of solvent flow. As an exemplary result, behind a third stretch-and-fold unit, practically perfect mixing (MI>0.9) is predicted at total flow rates between 50 µL/min and 400 µL/min and up to 20% solvent flow share. Based on MI values, the mixing time, which is decisive for the size and dispersity of the nanoparticles, can be determined. Under the conditions considered, it ranges from 5 ms to 54 ms. A good correlation between the predicted mixing time and nanoparticle properties, as experimentally observed in earlier work, could be confirmed. The digital twin combining CFD with the MI methodology can in the future be used to adjust the design of a CLM or other micromixers to the desired total flow rates and flow rate ratios and to provide valuable predictions for the mixing time and even the properties of nanoparticles produced by microfluidic antisolvent precipitation.

An optimal design of nanocarriers is required to overcome the gap between synthetic and biological identity, improving the clinical translation of nanomedicine. A new generation of hybrid vehicles based on lipid–polymer coupling, obtained by Microfluidics, is proposed and validated for theranostics and multimodal imaging applications. A coupled Hydrodynamic Flow Focusing (cHFF) is exploited to control the time scales of solvent exchange and the coupling of the polymer nanoprecipitation with the lipid self-assembly simultaneously, guiding the formation of Lipid–Polymer NPs (LiPoNs). This hybrid lipid–polymeric tool is made up of core–shell structure, where a polymeric chitosan core is enveloped in a lipid bilayer, capable of co-encapsulating simultaneously Gd-DTPA and Irinotecan/Atto 633 compounds. As a result, a monodisperse population of hybrid NPs with an average size of 77 nm, with preserved structural integrity in different environmental conditions and high biocompatibility, can be used for MRI and Optical applications. Furthermore, preliminary results show the enhanced delivery and therapeutic efficacy of Irinotecan-loaded hybrid formulation against U87 MG cancers cells.

The formation of micro-scale monodispersed emulsions is crucial for a variety of applications such as cosmetics, food industry and biotechnology. In this study, a new microfluidic chip with a multiple-channel layout for high-throughput emulsions is reported. This chip generated fine-tuned and uniform microdroplets in liquids with a higher throughput for emulsification applications. It employed a combination of multiple hydrodynamic flow focusing and liquid-cutting devices called \"active pneumatic choppers.\" Experimental data indicated that oil-in-water microdroplets with diameters ranging from 6 to 120 microm can be successfully generated with a coefficient of variation less than 3.75%. The size of the droplets can be actively fine-tuned by using two approaches by adjusting relative sheath/sample flow velocity ratios and chopping frequency. Finally, two commonly used biocompatible materials, including collagen and calcium-alginate (Ca-alginate), were used to form microspheres by utilizing the liquid-cutting technique. The developed microfluidic chip is promising in various applications including biotechnology, nano-medicine and cosmetics.

Inertial microfluidics (i.e., migration and focusing of particles in finite Reynolds number microchannel flows) is a passive, precise, and high-throughput method for microparticle manipulation and sorting. Therefore, it has been utilized in numerous biomedical applications including phenotypic cell screening, blood fractionation, and rare-cell isolation. Nonetheless, the applications of this technology have been limited to larger bioparticles such as blood cells, circulating tumor cells, and stem cells, because smaller particles require drastically longer channels for inertial focusing, which increases the pressure requirement and the footprint of the device to the extent that the system becomes unfeasible. Inertial manipulation of smaller bioparticles such as fungi, bacteria, viruses, and other pathogens or blood components such as platelets and exosomes is of significant interest. Here, we show that using oscillatory microfluidics, inertial focusing in practically “infinite channels” can be achieved, allowing for focusing of micron-scale (i.e. hundreds of nanometers) particles. This method enables manipulation of particles at extremely low particle Reynolds number (Rep < 0.005) flows that are otherwise unattainable by steady-flow inertial microfluidics (which has been limited to Rep > ∼10−1). Using this technique, we demonstrated that synthetic particles as small as 500 nm and a submicron bacterium, Staphylococcus aureus, can be inertially focused. Furthermore, we characterized the physics of inertial microfluidics in this newly enabled particle size and Rep range using a Peclet-like dimensionless number (α). We experimentally observed that α >> 1 is required to overcome diffusion and be able to inertially manipulate particles.

In the present study, we explore the dynamics of bubble formation in a flow-focusing device designed for gas-non-Newtonian liquid two-phase flow. The flow-focusing device with a cross-section of a square (300 μm × 300 μm) is constructed on polydimethylsiloxane using lithographic techniques and subsequently sealed with polymethylmethacrylate. A high-speed camera is employed to document the process of bubble formation during the experiment, complemented by computational fluid dynamics methods for an in-depth analysis. The gas is nitrogen, and the liquid is sodium carboxymethyl cellulose solutions with mass fractions of 0.1, 0.2, and 0.3%, respectively. The inlet flow rates of gas and liquid are set at 1–2 ml/min in the simulation and the experiment, and the observed flow patterns are all slug flows. Experimental findings suggest that the duration of bubble formation can be bifurcated into two distinct parts. The first part is predominantly influenced by the velocity of the inlet gas, and the correlation coefficient between velocity and time is −0.56, while the second part is impacted by the shear-thinning properties of the liquid, which are correlated with the flow index and viscosity coefficient of the non-Newtonian liquids, and the correlation coefficients are −0.47 and 0.48, respectively. The computational fluid dynamics results of gas-non-Newtonian liquid two-phase flow with gas and liquid flow rates of 2 ml/min corroborate that the manifestation of the aforementioned time segmentation phenomenon primarily depends on the vortex intensity at the bubble’s head and the orientation of pressure gradients. When the bubble neck size approaches 0, the viscosity of the surrounding liquid decreases rapidly, and alterations in the velocity field near the bubble neck trigger fluctuations in the viscosity of the non-Newtonian liquid, thereby influencing the bubble formation process.

The ecological interaction between bacteria and sinking particles, such as bacterial degradation of marine snow particles, is regulated by their encounters. Current encounter models focus on the diffusive regime, valid for particles larger than the bacterial run length, yet the majority of marine snow particles are small, and the encounter process is then ballistic. Here, we analytically and numerically quantify the encounter rate between sinking particles and non-motile or motile micro-organisms in the ballistic regime, explicitly accounting for the hydrodynamic shear created by the particle and its coupling with micro-organism shape. We complement results with selected experiments on non-motile diatoms. The shape-shear coupling has a considerable effect on the encounter rate and encounter location through the mechanisms of hydrodynamic focusing and screening, whereby elongated micro-organisms preferentially orient normally to the particle surface downstream of the particle (focusing) and tangentially to the surface upstream of the particle (screening). Non-motile elongated micro-organisms are screened from sinking particles because shear aligns them tangentially to the particle surface, which reduces the encounter rate by a factor proportional to the square of the micro-organism aspect ratio. For motile elongated micro-organisms, hydrodynamic focusing increases the encounter rate when particle sinking speed is similar to micro-organism swimming speed, whereas for very quickly sinking particles hydrodynamic screening can reduce the encounter rate below that of non-motile micro-organisms. For natural ocean conditions, we connect the ballistic and diffusive limits and compute the encounter rate as a function of shape, motility and particle characteristics. Our results indicate that shear should be taken into account to predict the interactions between bacteria and sinking particles responsible for the large carbon flux in the ocean's biological pump.

Microfluidic wet spinning has gained increasing interest in recent years as an alternative to conventional wet spinning by offering higher control in fiber morphology and a gateway for the development of multi-material fibers. Conventionally, microfluidic chips used to create such fibers are fabricated by soft lithography, a method that requires both time and investment in necessary cleanroom facilities. Recently, additive manufacturing techniques were investigated for rapid and cost-efficient prototyping. However, these microfluidic devices are not yet matching the resolutions and tolerances offered by soft lithography. Herein, we report a facile and rapid method using selected arrays of hypodermic needles as templates within a silicone elastomer matrix. The produced microfluidic spinnerets display co-axially aligned circular channels. By simulation and flow experiments, we prove that these devices can maintain laminar flow conditions and achieve precise 3D hydrodynamic focusing. The devices were tested with a commercial polyurethane formulation to demonstrate that fibers with desired morphologies can be produced by varying the degree of hydrodynamic focusing. Thanks to the adaptability of this concept to different microfluidic spinneret designs—as well as to its transparency, ease of fabrication, and cost-efficient procedure—this device sets the ground for transferring microfluidic wet spinning towards industrial textile settings.

Purpose This study aims to develop an experimentally validated three-dimensional numerical model for predicting different flow patterns produced with a gas dynamic virtual nozzle (GDVN). Design/methodology/approach The physical model is posed in the mixture formulation and copes with the unsteady, incompressible, isothermal, Newtonian, low turbulent two-phase flow. The computational fluid dynamics numerical solution is based on the half-space finite volume discretisation. The geo-reconstruct volume-of-fluid scheme tracks the interphase boundary between the gas and the liquid. To ensure numerical stability in the transition regime and adequately account for turbulent behaviour, the k-ω shear stress transport turbulence model is used. The model is validated by comparison with the experimental measurements on a vertical, downward-positioned GDVN configuration. Three different combinations of air and water volumetric flow rates have been solved numerically in the range of Reynolds numbers for airflow 1,009–2,596 and water 61–133, respectively, at Weber numbers 1.2–6.2. Findings The half-space symmetry allows the numerical reconstruction of the dripping, jetting and indication of the whipping mode. The kinetic energy transfer from the gas to the liquid is analysed, and locations with locally increased gas kinetic energy are observed. The calculated jet shapes reasonably well match the experimentally obtained high-speed camera videos. Practical implications The model is used for the virtual studies of new GDVN nozzle designs and optimisation of their operation. Originality/value To the best of the authors’ knowledge, the developed model numerically reconstructs all three GDVN flow regimes for the first time.

This work develops a microflow cytometer, based on a microfluidic chip for three-dimensional (3D) hydrodynamic focusing and a binary optical element (BOE) for shaping and homogenizing a laser beam. The microfluidic chip utilizes sheath flows to confine the sample flow along the channel centerline with a narrow cross section. In addition to hydrodynamic focusing, secondary flows are generated to strengthen the focusing in the vertical direction. In experiments, the chip was able to focus the sample flow with cross sections of 15 μm high and 8–30 μm wide at 5 m/s, under the condition of the sample flow rates between 10 and 120 μL/min. Instead of using the conventional elliptical Gaussian spot for optical detection, we used a specially designed BOE and obtained a 50 μm × 10 μm rectangular quasi-flat-top spot. The microflow cytometer combining the chip and the BOE was tested to count 3, 5, and 7 μm fluorescence microbeads, and the experimental results were comparable to or better than those derived from two commercial instruments.