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Image-based sensor systems are quite popular in micro-scale flow investigations due to their flexibility and scalability. The aim of this manuscript is to provide an overview of current technical possibilities for Particle Image Velocimetry (PIV) systems and related image processing tools used in microfluidics applications. In general, the PIV systems and related image processing tools can be used in a myriad of applications, including (but not limited to): Mixing of chemicals, droplet formation, drug delivery, cell counting, cell sorting, cell locomotion, object detection, and object tracking. The intention is to provide some application examples to demonstrate the use of image processing solutions to overcome certain challenges encountered in microfluidics. These solutions are often in the form of image pre- and post-processing techniques, and how to use these will be described briefly in order to extract the relevant information from the raw images. In particular, three main application areas are covered: Micro mixing, droplet formation, and flow around microscopic objects. For each application, a flow field investigation is performed using Micro-Particle Image Velocimetry (µPIV). Both two-component (2C) and three-component (3C) µPIV systems are used to generate the reported results, and a brief description of these systems are included. The results include detailed velocity, concentration and interface measurements for micromixers, phase-separated velocity measurements for the micro-droplet generator, and time-resolved (TR) position, velocity and flow fields around swimming objects. Recommendations on, which technique is more suitable in a given situation are also provided.

Micro-droplets are widely used in the fields of chemical and biological research, such as drug delivery, material synthesis, point-of-care diagnostics, and digital PCR. Droplet-based microfluidics has many advantages, such as small reagent consumption, fast reaction time, and independent control of each droplet. Therefore, various micro-droplet generation methods have been proposed, including T-junction breakup, capillary flow-focusing, planar flow-focusing, step emulsification, and high aspect (height-to-width) ratio confinement. In this study, we propose a microfluidic device for generating monodisperse micro-droplets, the microfluidic channel of which has an asymmetric cross-sectional shape and high hypotenuse-to-width ratio (HTWR). It was fabricated using basic MEMS processes, such as photolithography, anisotropic wet etching of Si, and polydimethylsiloxane (PDMS) molding. Due to the geometric similarity of a Si channel and a PDMS mold, both of which were created through the anisotropic etching process of a single crystal Si, the microfluidic channel with the asymmetric cross-sectional shape and high HTWR was easily realized. The effects of HTWR of channels on the size and uniformity of generated micro-droplets were investigated. The monodisperse micro-droplets were generated as the HTWR of the asymmetric channel was over 3.5. In addition, it was found that the flow direction of the oil solution (continuous phase) affected the size of micro-droplets due to the asymmetric channel structures. Two kinds of monodisperse droplets with different sizes were successfully generated for a wider range of flow rates using the asymmetric channel structure in the developed microfluidic device.

The objective of this research work is to propose a phase diagram that can be used to find a proper operating condition for generating droplets of different types. It is found that the phase diagram of QR versus CaD can effectively classify the droplet generation into three vivid regimes: dripping, jetting and tubing. For the dripping regime, its operating condition is in the range of either CaD < 10−4 and QR < 50 or 10−3 < CaD < 10−4 and QR < 1. For the jetting regime, its operating condition is in the range of either CaD < 1.35 × 10−2 and QR > 100 or CaD > 1.35 × 10−2 and QR > 1. For the tubing regime, its operating condition is in the range of CaD > 1.35 × 10−2 and QR < 1.

Microfluidic structures and devices have been studied over decades for the transport of liquid through internal channels using versatile microfabrication schemes such as surface and bulk micromachining technologies. One challenge in consideration of the device design involves the breakthrough of microfluidic reservoir and channels being substantially limited in two-dimensional (2D) geometry. However, recent progress of the emerging 3D printing technologies has showed great potential to overcome this problem in a simple manner. This paper comprehensively reports an additive manufacturing of polylactic acid (PLA) layers to significantly improve the complexity in the formation of the 3D microfluidic structures as compared to conventional micro-manufacturing techniques. Moreover, a handheld mechatronic device with a small height of ~10 mm, assembled with a thin planar atomizer and a micro controller, was produced and demonstrated for generation of droplets (~6 μm in diameter). Both the analytical and experimental results indicated that the grids of channel microstructures were simply varied by different line widths (300–500 μm) and spacing (250–400 μm) 3D printed within the device, thereby providing the design capability for capillary flow. In this regard, a variety of complex micro devices fabricated via computer-aided design (CAD) and the 3D printing method could be applied for more applications than ever, such as microfluidic delivery of biomedical materials and health care devices of a small size.

This study focuses on utilizing a novel method, the droplet generation method (DGM), to prepare hybrid nanofluids. The aim is to compare thermophysical properties, including thermal conductivity (TC) and viscosity, and magnetic properties between the DGM and two-step method (TSM). To prepare a bio-nanofluid, both fluid and nanoparticles must be biocompatible. Therefore, simulated body fluid (SBF) and olive oil were used to prepare this hybrid bio-nanofluid, and for the magnetic particle, iron oxide (Fe 3 O 4 ) was used. Phase and microstructural examinations were conducted using XRD, FTIR, and FE-SEM. The KD2 Pro and DV2 Pro devices were employed to measure the thermal conductivity and viscosity of the samples, respectively. For both samples prepared using DGM and TSM, different volume fractions ranging from 0.01% to 1.00% and temperatures varying from 20°C to 40°C were measured individually. In TSM, from 20°C to 40°C, for 0.10% and 1.00% v.v, TC increased by 6.31% and 10.14%, respectively, while in DGM, it decreased by 0.48% and 1.23%, respectively. At a shear rate of 12.23 s −1 , from 20°C to 40°C, for 0.10% and 1.00% v.v, in the TSM, the viscosity decreased by 31.39% and 34.99%, respectively, while in DGM, it decreased by 25.11% and 28.83%, respectively. At a shear rate of 122.3 s −1 , from 20°C to 40°C, for 0.10% and 1.00% v.v, in the TSM, the viscosity decreased by 22.92% and 29.25%, respectively, while in DGM, it decreased by 17.42% and 23.85%, respectively. The results of this study contribute to understanding the effect of DGM on altering thermophysical properties of bio-nanofluids.

For the research on droplet deformation and breakup in scaled high-pressure homogenizing units, a pressure stable inline droplet generator was developed. It consists of an optically accessible flow channel with a combination of stainless steel and glass capillaries and a 3D printed orifice. The droplet size is determined online by live image analysis. The influence of the orifice diameter, the mass flow of the continuous phase and the mass flow of the disperse phase on the droplet diameter were investigated. Furthermore, the droplet detachment mechanisms were identified. Droplet diameters with a small diameter fluctuation between 175 µm and 500 µm could be realized, which allows a precise adjustment of the capillary (Ca) and Weber (We) Number in the subsequent scaled high pressure homogenizer disruption unit. The determined influence of geometry and process parameters on the resulting droplet size and droplet detachment mechanism agreed well with the literature on microfluidics. Furthermore, droplet trajectories in an exemplary scaled high-pressure homogenizer disruption unit are presented which show that the droplets can be reinjected on a trajectory close to the center axis or close to the wall, which should result in different stresses on the droplets.

In solid-phase peptide synthesis (SPPS), a high concentration of functional groups on the solid support and an adequate swelling volume enables its use for high-throughput screening of receptor agonists and therapeutic peptides. However, a high resin loading often leads to insufficient purity of the synthesized peptides and false positive binding with the target due to improper interactions between neighboring peptides. Therefore, this study focused on low-loaded polyethylene glycol (PEG) resins to achieve high-specificity screening using a core–shell-type PEG hydrogel resin. The peptide purity and target specificity were determined by assessing (1) the resin swelling properties in various solvents, (2) purity of a complicated Jung-Redemann (JR) decapeptide, and (3) the cell-adhesive behavior of GRGDS-pentapeptide-bound resins. The results were compared with those obtained using polyacrylamide resin (PAM) and conventionally used TentaGel S NH 2 resin (TG ® ). The highest JR decapeptide purity was achieved using the PEG-based resin with a higher degree of cross-linking (PEGHN). Furthermore, the resin was preferably qualified as an extracellular microenvironment to accommodate true specific binding with fibroblast cells. Thus, SPPS and cell binding assays using the developed PEG-based resin provide a novel stringent strategy with potential application for true positive screening in biological assays.

Controlling droplet sizes is one of the most important aspects of droplet generators used in biomedical research, drug discovery, high-throughput screening, and emulsion manufacturing applications. This is usually achieved by using multiple devices that are restricted in their range of generated droplet sizes. In this paper, a co-flow microfluidic droplet-generation device with flexible walls was developed such that the width of the continuous (C)-phase channel around the dispersed (D)-phase droplet-generating needle can be adjusted on demand. This actuation mechanism allowed for the adjustment of the C-phase flow velocity, hence providing modulated viscous forces to manipulate droplet sizes in a single device. Two distinct droplet-generation regimes were observed at low D-phase Weber numbers, i.e., a dripping regime at high- and medium-channel widths and a plug regime at low-channel widths. The effect of channel width on droplet size was investigated in the dripping regime under three modes of constant C-phase flow rate, velocity, and Capillary number. Reducing the channel width at a constant C-phase flow rate had the most pronounced effect on producing smaller droplets. This effect can be attributed to the combined influences of the wall effect and increased C-phase velocity, leading to a greater impact on droplet size due to the intensified viscous force. Droplet sizes in the range of 175–913 µm were generated; this range was ~2.5 times wider than the state of the art, notably using a single microfluidic device. Lastly, an empirical model based on Buckingham’s Pi theorem was developed to predict the size of droplets based on channel width and height as well as the C-phase Capillary and Reynolds numbers.

Microfluidic techniques allow for the tailored construction of specific microparticles, which are becoming increasingly interesting and relevant. Here, using a microfluidic hole-plate-device and thermal-initiated free radical polymerization, submicrometer polymer particles with a highly textured surface were synthesized. Two types of monomers were applied: (1) methylmethacrylate (MMA) combined with crosslinkers and (2) divinylbenzene (DVB). Surface texture and morphology can be influenced by a series of parameters such as the monomer–crosslinker–solvent composition, surfactants, and additives. Generally, the most structured surfaces with the simultaneously most uniform particles were obtained in the DVB–toluene–nonionic-tensides system. In a second approach, poly-MMA (PMMA) particles were used to build aggregates with bigger polymer particles. For this purpose, tripropyleneglycolediacrylate (TPGDA) particles were synthesized in a microfluidic co-flow arrangement and polymerized by light- irradiation. Then, PMMA particles were assembled at their surface. In a third step, these composites were dispersed in an aqueous acrylamide–methylenebisacrylamide solution, which again was run through a co-flow-device and photopolymerized. As such, entities consisting of particles of three different size ranges—typically 0.7/30/600 µm—were obtained. The particles synthesized by both approaches are potentially suitable for loading with or incorporation of analytic probes or catalysts such as dyes or metals.