An acoustofluidic micromixer via bubble inception and cavitation from microchannel sidewalls

Acoustophoresis-driven particle focusing and separation with standard/inverse Chladni patterns

Manipulating objects with acoustics has been developed for hundreds of years since Chladni patterns in gaseous environments were exhibited. In recent decades, acoustic manipulation in microfluidics, known as acoustofluidics, has rapidly thrived and many sophisticated technologies were born. However, the basic background motion of particles under acoustic excitation is usually neglected and the classical Chladni patterns haven't been reproduced in an aqueous environment. In this study, we investigated the basic mechanism and the motion of suspended particles and sinking particles in a plain microchamber under low-frequency excitation (3-5 kHz). The mechanisms were clearly distinguished by comparing the differences among colored fluids, suspended particles, and sinking particles. The suspended particles rotated around the antinode with a speed up to 55.1 μm s-1 at 100 Vpp by the acoustic streaming and they approached each other by the secondary acoustic radiation force. The sinking particles concentrated at the node with a speed up to 22.3 μm s-1 at 100 Vpp by bouncing on the vibrating surface and the primary acoustic radiation force. We have reproduced the classical standard/inverse Chladni patterns in an aqueous environment for the first time, and they were leveraged to separate SiO2 particles with different sizes. The big particles with an average diameter of 9.68 μm were concentrated at the node while the small particles with an average diameter of 2.72 μm were collected at the antinode within 2 min. These results not only provide insightful perspectives of basic mechanisms, but also open up new possibilities for advanced acoustic tweezers.

Enhanced Performance of an Acoustofluidic Device by Integrating Temperature Control

Acoustofluidics is an emerging research field wherein either mixing or (bio)-particle separation is conducted. High-power acoustic streaming can produce more intense and rapid flow patterns, leading to faster and more efficient liquid mixing. However, without cooling, the temperature of the piezoelectric element that is used to supply acoustic power to the fluid could rise above 50% of the Curie point of the piezomaterial, thereby accelerating its aging degradation. In addition, the supply of excessive heat to a liquid may lead to irreproducible streaming effects and gas bubble formation. To control these phenomena, in this paper, we present a feedback temperature control system integrated into an acoustofluidic setup using bulk acoustic waves (BAWs) to elevate mass transfer and manipulation of particles. The system performance was tested by measuring mixing efficiency and determining the average velocity magnitude of acoustic streaming. The results show that the integrated temperature control system keeps the temperature at the set point even at high acoustic powers and improves the reproducibility of the acoustofluidic setup performance when the applied voltage is as high as 200 V.

An overview on state-of-art of micromixer designs, characteristics and applications

Micromixers are characterized based on characteristics such as excellent mixing efficiency, low reagent cost and flexible controllability compared with conventional reactors in terms of macro size. A variety of designs and applications of micromixers have been proposed. The focus of current reviews is restricted to micromixer structures. Each type of micromixer has characteristics corresponding to its structure, which determines the suitable application areas. This paper provides an overview connecting micromixer designs and their applications. First, the typical designs and mixing mechanisms of both passive and active micromixers are summarized. Then, application cases of micromixers, including chemical, biological and medical applications, are presented. The characteristics, including the advantages and restrictions of different micromixers, are discussed. Finally, the future perspective of micromixer design is proposed. It is predictable that micromixers will have widespread applications by integrating two or more different mixing methods together. This review would be beneficial to guide the design of micromixers applied for specific purposes.

Acoustophoresis around an elastic scatterer in a standing wave field

Acoustofluidic systems often employ prefabricated acoustic scatterers that perturb the imposed acoustic field to realize the acoustophoresis of immersed microparticles. We present a numerical study to investigate the time-averaged streaming and radiation force fields around a scatterer. Based on the streaming and radiation force field, we obtain the trajectories of the immersed microparticles with varying sizes and identify a critical transition size at which the motion of immersed microparticles in the vicinity of a prefabricated scatterer shifts from being streaming dominated to radiation dominated. We consider a range of acoustic frequencies to reveal that the critical transition size decreases with increasing frequency; this result explains the choice of acoustic frequencies in previously reported experimental studies. We also examine the impact of scatterer material and fluid properties on the streaming and radiation force fields, as well as on the critical transition size. Our results demonstrate that the critical transition size decreases with an increase in acoustic contrast factor: a nondimensional quantity that depends on material properties of the scatterer and the fluid. Our results provide a pathway to realize radiation force based manipulation of small particles by increasing the acoustic contrast factor of the scatterer, lowering the kinematic viscosity of the fluid, and increasing the acoustic frequency.

A Miniaturized Archimedean Screw Pump for High-Viscosity Fluid Pumping in Microfluidics

Microfluidic devices have revolutionized the field of lab-on-a-chip by enabling precise manipulation of small fluid volumes for various biomedical applications. However, most existing microfluidic pumps struggle to handle high-viscosity fluids, limiting their applicability in certain areas that involve bioanalysis and on-chip sample processing. In this paper, the design and fabrication of a miniaturized Archimedean screw pump for pumping high-viscosity fluids within microfluidic channels are presented. The pump was 3D-printed and operated vertically, allowing for continuous and directional fluid pumping. The pump's capabilities were demonstrated by successfully pumping polyethylene glycol (PEG) solutions that are over 100 times more viscous than water using a basic mini-DC motor. Efficient fluid manipulation at low voltages was achieved by the pump, making it suitable for point-of-care and field applications. The flow rates of water were characterized, and the effect of different screw pitch lengths on the flow rate was investigated. Additionally, the pump's capacity for pumping high-viscosity fluids was demonstrated by testing it with PEG solutions of increasing viscosity. The microfluidic pump's simple fabrication and easy operation position it as a promising candidate for lab-on-a-chip applications involving high-viscosity fluids.

Acoustofluidic large-scale mixing for enhanced microfluidic immunostaining for tissue diagnostics

The usage of microfluidics for automated and fast immunoassays has gained a lot of interest in the last decades. This integration comes with certain challenges, like the reconciliation of laminar flow patterns of micro-scale systems with diffusion-limited mass transport. Several methods have been investigated to enhance microfluidic mixing in microsystems, including acoustic-based fluidic streaming. Here, we report both by numerical simulation and experiments on the beneficiary effect of acoustic agitation on the uniformity of immunostaining in large-size and thin microfluidic chambers. Moreover, we investigate by numerical simulation the impact of reducing the incubation times and the concentrations of the biochemical detection reagents on the obtained immunoassay signal. Finally, acoustofluidic mixing was successfully used to reduce by 80% the incubation time of the Her2 (human epidermal growth factor receptor 2) and CK (cytokeratins) biomarkers for the spatial immunostaining of breast cancer cell pellets, or reducing their concentration by 66% and achieving a higher signal-to-background ratio than comparable spatially resolved immunostaining with static incubation.

Efficient AC electrothermal flow (ACET) on-chip for enhanced immunoassays

Biochemical reaction rates in microfluidic systems are known to be limited by the diffusional transport of reagents, leading often to lowered sensitivity and/or longer detection times in immunoassays. Several methods, including electrically powering electrodes to generate AC electrothermal flow (ACET) on-chip, have been adopted to enhance the mass transport of the reagents and improve microfluidic mixing. Here, we report a novel ACET electrode design concept for generating in-plane microfluidic mixing vortices that act over a large volume close to the reaction surface of interest. This is different from the traditional ACET parallel electrode design that provides rather local vertical mixing vortices directly above the electrodes. Both numerical simulation and experimental studies were performed to validate the new design. Moreover, numerical simulation was carried out to show the effects of experimental factors such as the reaction kinetics (association constant) and the reagent concentration on the ACET-enhanced surface-based assays. As a proof of concept, the new design for the ACET-enhanced immunoassays was used to improve the immunostaining signal of the HER2 (human epidermal growth factor receptor 2) cancer biomarker on breast cancer cells. Finally, the concept of scaling up the design has been validated by experiments (immunoassays on breast cancer cells for different ACET power and different assay times). In particular, we show that larger ACET in-plane designs can agitate and mix the fluid over large microfluidic volumes, which further enhances the immunoassay's output. We have achieved a 6-times enhancement in the assay signal with a 75% reduction in assay time.

Emulsification mechanism in an ultrasonic microreactor: Influence of surface roughness and ultrasound frequency

An ultrasonic microreactor with rough microchannels is presented in this study for oil-in-water (O/W) emulsion generation. Previous accounts have shown that surface pits or imperfections localize and enhance cavitation activity. In this study cavitation bubbles are localized on the rough microchannels of a borosilicate glass microreactor. The cavitation bubbles in the microchannel are primarily responsible for emulsification in the ultrasonic microreactor. We investigate the emulsification mechanism in the rough microchannels employing high-speed imaging to reveal the different emulsification modes influenced by the size and oscillation intensity of the cavitation bubbles. The effect of emulsification modes on the O/W emulsion droplet size distribution for different surface roughness and frequency is demonstrated. The positive effect of the frequency on minimizing the droplet size utilizing a reactor with large pits is presented. We also demonstrate microreactor systems for a successful generation of miniemulsions with high dispersed phase volume fractions up to 20%. The observed emulsification mechanism in the rough microchannel offers new insights into the utility and scale-up of ultrasonic microreactors for emulsification.

A review on microfluidic-assisted nanoparticle synthesis, and their applications using multiscale simulation methods

Recent years have witnessed an increased interest in the development of nanoparticles (NPs) owing to their potential use in a wide variety of biomedical applications, including drug delivery, imaging agents, gene therapy, and vaccines, where recently, lipid nanoparticle mRNA-based vaccines were developed to prevent SARS-CoV-2 causing COVID-19. NPs typically fall into two broad categories: organic and inorganic. Organic NPs mainly include lipid-based and polymer-based nanoparticles, such as liposomes, solid lipid nanoparticles, polymersomes, dendrimers, and polymer micelles. Gold and silver NPs, iron oxide NPs, quantum dots, and carbon and silica-based nanomaterials make up the bulk of the inorganic NPs. These NPs are prepared using a variety of top-down and bottom-up approaches. Microfluidics provide an attractive synthesis alternative and is advantageous compared to the conventional bulk methods. The microfluidic mixing-based production methods offer better control in achieving the desired size, morphology, shape, size distribution, and surface properties of the synthesized NPs. The technology also exhibits excellent process repeatability, fast handling, less sample usage, and yields greater encapsulation efficiencies. In this article, we provide a comprehensive review of the microfluidic-based passive and active mixing techniques for NP synthesis, and their latest developments. Additionally, a summary of microfluidic devices used for NP production is presented. Nonetheless, despite significant advancements in the experimental procedures, complete details of a nanoparticle-based system cannot be deduced from the experiments alone, and thus, multiscale computer simulations are utilized to perform systematic investigations. The work also details the most common multiscale simulation methods and their advancements in unveiling critical mechanisms involved in nanoparticle synthesis and the interaction of nanoparticles with other entities, especially in biomedical and therapeutic systems. Finally, an analysis is provided on the challenges in microfluidics related to nanoparticle synthesis and applications, and the future perspectives, such as large-scale NP synthesis, and hybrid formulations and devices.

Transition from Boundary-Driven to Bulk-Driven Acoustic Streaming Due to Nonlinear Thermoviscous Effects at High Acoustic Energy Densities

Acoustic streaming at high acoustic energy densities E_{ac} is studied in a microfluidic channel. It is demonstrated theoretically, numerically, and experimentally with good agreement that frictional heating can alter the streaming pattern qualitatively at high E_{ac} above 400  J/m^{3}. The study shows how as a function of increasing E_{ac} at fixed frequency, the traditional boundary-driven four streaming rolls created at a half-wave standing-wave resonance transition into two large streaming rolls. This nonlinear transition occurs because friction heats up the fluid resulting in a temperature gradient, which spawns an acoustic body force in the bulk that drives thermoacoustic streaming.

Microfluidic Acoustic Method for High Yield Extraction of Cell-Free DNA in Low-Volume Plasma Samples

Cell-free DNA has many applications in clinical medicine, in particular in cancer diagnosis and cancer treatment monitoring. Microfluidic-based solutions could provide solutions for rapid, cheaper, decentralized detection of cell-free tumoral DNA from a simple blood draw, or liquid biopsies, replacing invasive procedures or expensive scans. In this method, we present a simple microfluidic system for the extraction of cell-free DNA from low volume of plasma samples (≤500 μL). The technique is suitable for either static or continuous flow systems and can be used as a stand-alone module or integrated within a lab-on-chip system. The system relies on a simple yet highly versatile bubble-based micromixer module whose custom components can be fabricated with a combination of low-cost rapid prototyping techniques or ordered via widely available 3D-printing services. This system is capable of performing cell-free DNA extractions from small volumes of blood plasma with up to a tenfold increase in capture efficiency when compared to control methods.

Fundamentals, biomedical applications and future potential of micro-scale cavitation-a review

Thanks to the developments in the area of microfluidics, the cavitation-on-a-chip concept enabled researchers to control and closely monitor the cavitation phenomenon in micro-scale. In contrast to conventional scale, where cavitation bubbles are hard to be steered and manipulated, lab-on-a-chip devices provide suitable platforms to conduct smart experiments and design reliable devices to carefully harness the collapse energy of cavitation bubbles in different bio-related and industrial applications. However, bubble behavior deviates to some extent when confined to micro-scale geometries in comparison to macro-scale. Therefore, fundamentals of micro-scale cavitation deserve in-depth investigations. In this review, first we discussed the physics and fundamentals of cavitation induced by tension-based as well as energy deposition-based methods within microfluidic devices and discussed the similarities and differences in micro and macro-scale cavitation. We then covered and discussed recent developments in bio-related applications of micro-scale cavitation chips. Lastly, current challenges and future research directions towards the implementation of micro-scale cavitation phenomenon to emerging applications are presented.

A cross-mixing channel 3D-SAR micromixer with high mixing performance

As an important part of laboratory-on-a-chip (LOC) and micro-total analysis system (μTAS), micromixers are widely used in the fields of biological analysis and chemical synthesis. Most of them are used for the pretreatment of the detection and analysis system to realize the full mixing between the sample and the target to improve the accuracy of the inspection system. A new type of 3D-SAR micromixer with cross-channel structures was put forward after the systemic simulation by using CFD software. The mixing performance and mechanism of 3D-SAR micromixer with/without cross-mixing channel has been investigated with different Reynolds numbers (Re). The results show that the 3D-SAR micromixer with or without cross-mixing channel structures are of excellent mixing performance when the Re was high (Re > 50), and the mixing index is close to 1. While the concentration stratification of the two fluids in the cross-mixing channel (CMC) 3D-SAR micromixer is obviously better than that of no-cross-mixing channel (NCMC) 3D-SAR micromixer when Re is low (Re < 10). It is because the two fluids in the cross-mixing channel rotate counterclockwise at the mixing unit, which induces a vortex and increases the contact area between the two fluids. The mixing performance is greatly improved, and the mixing index at the outlet is more than 0.9. Meanwhile, in order to optimize the higher pressure drop of the CMC micromixer, a new 3D-SAR micromixer with the unbalanced-cross-mixing channel (UCMC) is proposed based on the CMC structure. This channel structure can meet the requirements of high mixing index and low-pressure drop at the same time, which is helpful to design and manufacture of new type micromixer.

A Numerical Investigation of the Mixing Performance in a Y-Junction Microchannel Induced by Acoustic Streaming

In this study, the mixing performance in a Y-junction microchannel with acoustic streaming was investigated through numerical simulation. The acoustic streaming is created by inducing triangular structures at the junction and sidewalls regions. The numerical model utilizes Navier-Stokes equations in conjunction with the convection-diffusion equations. The parameters investigated were inlet velocities ranging from 4.46 to 55.6 µm/s, triangular structure's vertex angles ranging from 22° to 90° oscillation amplitude ranging from 3 to 6 µm, and an oscillation frequency set to 13 kHz. The results show that at the junction region, a pair of counter-rotating streaming vortices were formed, and unsymmetrical or one-sided vortices were formed when additional triangles were added along the sidewalls. These streaming flows significantly increase the vorticity compared with the case without the acoustic stream. Mixing performances were found to have improved with the generation of the acoustic stream. The mixing performance was evaluated at various inlet velocities, the vertex angles of the triangular structure, and oscillation amplitudes. The numerical results show that adding the triangular structure at the junction region considerably improved the mixing efficiency due to the generation of acoustic streaming, and further improvements can be achieved at lower inlet velocity, sharper vertex angle, and higher oscillation amplitude. Integrating with more triangular structures at the sidewall regions also improves the mixing performance within the laminar flow regime in the Y-microchannel. At Y = 2.30 mm, oscillation amplitude of 6 µm, and flow inlet velocity of 55.6 µm/s, with all three triangles integrated and the triangles' vertex angles fixed to 30°, the mixing index can achieve the best results of 0.9981, which is better than 0.8355 in the case of using only the triangle at the junction, and 0.6642 in the case without acoustic streaming. This is equal to an improvement of 50.27% in the case of using both the junction and the two sidewall triangles, and 25.79% in the case of simply using a junction triangle.

A simple acoustofluidic device for on-chip fabrication of PLGA nanoparticles

Miniaturization of systems and processes provides numerous benefits in terms of cost, reproducibility, precision, minimized consumption of chemical reagents, and prevention of contamination. The field of microfluidics successfully finds a place in a plethora of applications, including on-chip nanoparticle synthesis. Compared with the bulk approaches, on-chip methods that are enabled by microfluidic devices offer better control of size and uniformity of fabricated nanoparticles. However, these microfluidic devices generally require complex and expensive fabrication facilities that are not readily available in low-resourced laboratories. Here, a low-cost and simple acoustic device is demonstrated by generating acoustic streaming flows inside glass capillaries through exciting different flexural modes. At distinct frequencies, the flexural modes of the capillary result in different oscillation profiles that can insert harmonic forcing into the fluid. We explored these flexural modes and identified the modes that can generate strong acoustic streaming vortices along the glass capillary. Then, we applied these modes for fluid mixing using an easy-to-fabricate acoustofluidic device architecture. This device is applied in the fabrication of poly(d,l-lactide-co-glycolide) (PLGA) nanoparticles. The acoustic device consists of a thin glass capillary and two polydimethylsiloxane adaptors that are formed using three-dimensional printed molds. By controlling the flow rates of the polymer and water solutions, PLGA nanoparticles with diameters between 65 and 96 nm are achieved with polydispersity index values ranging between 0.08 and 0.18. Owing to its simple design and minimal fabrication requirements, the proposed acoustofluidic mixer can be applied for microfluidic fluid mixing applications in limited resource settings.

Effect of microchannel protrusion on the bulk acoustic wave-induced acoustofluidics: numerical investigation

Acoustofluidics inside the microchannel has already found its wide applications recently. Acoustic streaming and radiation force are two underlying mechanisms that determine the trajectory of microparticles and cells in the manipulation. Critical particle size of viscous effects is found to be about 1.6 µm in the conventional rectangular microchannel (W × H = 380 m × 160 m) at the frequency of 2 MHz, below which the acoustic streaming dominants, and is independent of the driving voltage. In order to effectively adjust such a critical size, a approach is proposed and evaluated numerically to enhance the acoustic streaming by adding some protrusions (i.e., in the shape of a wedge, rod, half-ellipse) to the middle of the top or bottom wall. It is found that the resonant frequency and acoustic pressure will decrease and the acoustic streaming velocity will increase significantly, respectively, with the increase of protrusion height (up to 30 µm while keeping the width the same as 8 µm). Subsequently, trajectory motion patterns of microparticles have apparent changes in comparison to those inside the rectangular microchannel, and acoustic streaming can even dominate the motion of large microparticles (i.e., 10 µm). As a result, the critical particle size could be increased up to 72.5 µm. Furthermore, different protrusion shapes (i.e., wedge, rod, half-ellipse) on the top wall were compared. The sharpness of protrusion at its tip seems to determine the acoustic streaming velocity. The wedge attached to the bottom wall had higher resonant frequency and lower acoustic streaming velocity compared with the top wedge in the same dimension. The patterns of acoustic streaming and microparticle trajectory motion in the microchannel with dual wedges on the top and bottom walls are not the superposition of those of the top and bottom wedge individually. In summary, the geometry of the microchannel has a significant effect on the induced acoustofluidics by the bulk acoustic waves. A much larger acoustic streaming velocity is produced at the tip of the protrusion to change the critical size of microparticles between acoustic streaming and radiation force. It suggests that more applications of acoustofluidics (i.e., mixing and sonoporation) to microparticles and cells in various sizes are feasible by designing an appropriate geometry of the microchannel.

Light fueled mixing in open surface droplet microfluidics for rapid probe preparation

In this study, a contactless, flexible, and interference-free light fueled method has been developed to enhance the mixing between the ssDNA and dynabeads in a droplet, which enables rapid probe preparation for promoting the probe technology based on open surface droplet microfluidics. In this light fueled method, the use of the photothermal effect of a focused infrared laser can easily create non-uniform temperature distribution and accordingly the surface tension gradient over the interface as a result of the localized heating effect, which thereby initiates the Marangoni flow in a droplet. Experimental results confirm that the light-induced Marangoni flow greatly enhances the mixing, ensuring rapid and efficient binding between the ssDNA and dynabeads. Moreover, the mixing intensity and degree can be simply tuned by controlling the laser intensity and laser heating time. The light fueled rapid mixing method developed in the present study paves the way for rapid bio-chemical detection.

Rapid Microfluidic Mixing Method Based on Droplet Rotation Due to PDMS Deformation

Droplet-based micromixers have shown great prospects in chemical synthesis, pharmacology, biologics, and diagnostics. When compared with the active method, passive micromixer is widely used because it relies on the droplet movement in the microchannel without extra energy, which is more concise and easier to operate. Here we present a droplet rotation-based microfluidic mixer that allows rapid mixing within individual droplets efficiently. PDMS deformation is used to construct subsidence on the roof of the microchannel, which can deviate the trajectory of droplets. Thus, the droplet shows a rotation behavior due to the non-uniform distribution of the flow field, which can introduce turbulence and induce cross-flow enhancing 3D mixing inside the droplet, achieving rapid and homogenous fluid mixing. In order to evaluate the performance of the droplet rotation-based microfluidic mixer, droplets with highly viscous fluid (60% w/w PEGDA solution) were generated, half of which was seeded with fluorescent dye for imaging. Mixing efficiency was quantified using the mixing index (MI), which shows as high as 92% mixing index was achieved within 12 mm traveling. Here in this work, it has been demonstrated that the microfluidic mixing method based on the droplet rotation has shown the advantages of low-cost, easy to operate, and high mixing efficiency. It is expected to find wide applications in the field of pharmaceutics, chemical synthesis, and biologics.

Fabrication of tunable, high-molecular-weight polymeric nanoparticles via ultrafast acoustofluidic micromixing

High-molecular-weight polymeric nanoparticles are critical to increasing the loading efficacy and tuning the release profile of targeted molecules for medical diagnosis, imaging, and therapeutics. Although a number of microfluidic approaches have attained reproducible nanoparticle synthesis, it is still challenging to fabricate nanoparticles from high-molecular-weight polymers in a size and structure-controlled manner. In this work, an acoustofluidic platform is developed to synthesize size-tunable, high-molecular-weight (>45 kDa) poly(lactic-co-glycolic acid)-b-poly(ethylene glycol) (PLGA-PEG) nanoparticles without polymer aggregation by exploiting the characteristics of complete and ultrafast mixing. Moreover, the acoustofluidic approach achieves two features that have not been achieved by existing microfluidic approaches: (1) multi-step (≥2) sequential nanoprecipitation in a single device, and (2) synthesis of core-shell structured PLGA-PEG/lipid nanoparticles with high molecular weights. The developed platform expands microfluidic potential in nanomaterial synthesis, where high-molecular-weight polymers, multiple reagents, or sequential nanoprecipitations are needed.

Ultrasound-assisted production and optimization of mini-emulsions in a microfluidic chip in continuous-flow

The use of ultrasound to generate mini-emulsions (50 nm to 1 μm in diameter) and nanoemulsions (mean droplet diameter < 200 nm) is of great relevance in drug delivery, particle synthesis and cosmetic and food industries. Therefore, it is desirable to develop new strategies to obtain new formulations faster and with less reagent consumption. Here, we present a polydimethylsiloxane (PDMS)-based microfluidic device that generates oil-in-water or water-in-oil mini-emulsions in continuous flow employing ultrasound as the driving force. A Langevin piezoelectric attached to the same glass slide as the microdevice provides enough power to create mini-emulsions in a single cycle and without reagents pre-homogenization. By introducing independently four different fluids into the microfluidic platform, it is possible to gradually modify the composition of oil, water and two different surfactants, to determine the most favorable formulation for minimizing droplet diameter and polydispersity, employing less than 500 µL of reagents. It was found that cavitation bubbles are the most important mechanism underlying emulsions formation in the microchannels and that degassing of the aqueous phase before its introduction to the device can be an important factor for reduction of droplet polydispersity. This idea is demonstrated by synthetizing solid polymeric particles with a narrow size distribution starting from a mini-emulsion produced by the device.

A review on acoustic field-driven micromixers

A review on acoustic field-driven micromixers is given. This is supplemented by the governing equations, governing non-dimensional parameters, numerical simulation approaches, and fabrication techniques. Acoustically induced vibration is a kind of external energy input employed in active micromixers to improve the mixing performance. An air bubble energized by an acoustic field acts as an external energy source and induces friction forces at the interface between an air bubble and liquid, leading to the formation of circulatory flows. The current review (with 200 references) evaluates different characteristics of microfluidic devices working based on acoustic field shaking.

Mixing characteristics of a bubble mixing microfluidic chip for genomic DNA extraction based on magnetophoresis: CFD simulation and experiment

Mixing a small amount of magnetic beads and regents with large volume samples evenly in microcavities of a microfluidic chip is always the key step for the application of microfluidic technology in the field of magnetophoresis analysis. This article proposes a microfluidic chip for DNA extraction by magnetophoresis, which relies on bubble rising to generate turbulence and microvortices of various sizes to mix magnetic beads with samples uniformly. The construction and working principle of the microfluidic chip are introduced. CFD simulations are conducted when magnetic beads and samples are irritated by the generation of gas bubbles with the variation of supply pressures. The whole mixing process in the microfluidic chip is observed through a high-speed camera and a microfluidic system when the gas bubbles are generated continuously. The influence of supply pressure on the mixing characteristics of the microfluidic chip is investigated and discussed with both simulation and experiments. Compared with magnetic mixing, bubble mixing can avoid the magnetic beads gather phenomenon caused by magnetic forces and provide a rapid and high efficient solution to realize mixing small amount of regents in large volume samples in a certain order without complex moving structures and operations in a chip. Two applications of mixing with the proposed microfluidic chip are also carried out and discussed.

Nanomaterials Synthesis through Microfluidic Methods: An Updated Overview

Microfluidic devices emerged due to an interdisciplinary "collision" between chemistry, physics, biology, fluid dynamics, microelectronics, and material science. Such devices can act as reaction vessels for many chemical and biological processes, reducing the occupied space, equipment costs, and reaction times while enhancing the quality of the synthesized products. Due to this series of advantages compared to classical synthesis methods, microfluidic technology managed to gather considerable scientific interest towards nanomaterials production. Thus, a new era of possibilities regarding the design and development of numerous applications within the pharmaceutical and medical fields has emerged. In this context, the present review provides a thorough comparison between conventional methods and microfluidic approaches for nanomaterials synthesis, presenting the most recent research advancements within the field.

Bubbles in microfluidics: an all-purpose tool for micromanipulation

In recent decades, the integration of microfluidic devices and multiple actuation technologies at the microscale has greatly contributed to the progress of related fields. In particular, microbubbles are playing an increasingly important role in microfluidics because of their unique characteristics that lead to specific responses to different energy sources and gas-liquid interactions. Many effective and functional bubble-based micromanipulation strategies have been developed and improved, enabling various non-invasive, selective, and precise operations at the microscale. This review begins with a brief introduction of the morphological characteristics and formation of microbubbles. The theoretical foundations and working mechanisms of typical micromanipulations based on acoustic, thermodynamic, and chemical microbubbles in fluids are described. We critically review the extensive applications and the frontline advances of bubbles in microfluidics, including microflow patterns, position and orientation control, biomedical applications, and development of bubble-based microrobots. We lastly present an outlook to provide directions for the design and application of microbubble-based micromanipulation tools and attract the attention of relevant researchers to the enormous potential of microbubbles in microfluidics.

Trapping and control of bubbles in various microfluidic applications

As a simple, clean and effective tool, micro bubbles have enabled advances in various lab on a chip (LOC) applications recently. In bubble-based microfluidic applications, techniques for capturing and controlling the bubbles play an important role. Here we review active and passive techniques for bubble trapping and control in microfluidic applications. The active techniques are categorized based on various types of external forces from optical, electric, acoustic, mechanical and thermal fields. The passive approaches depend on surface tension, focusing on optimization of microgeometry and modification of surface properties. We discuss control techniques of size, location and stability of microbubbles and show how these bubbles are employed in various applications. To finalize, by highlighting the advantages of these approaches along with the current challenges, we discuss the future prospects of bubble trapping and control in microfluidic applications.

Understanding Interdependencies between Mechanical Velocity and Electrical Voltage in Electromagnetic Micromixers

Micromixers are critical components in the lab-on-a-chip or micro total analysis systems technology found in micro-electro-mechanical systems. In general, the mixing performance of the micromixers is determined by characterising the mixing time of a system, for example the time or number of circulations and vibrations guided by tracers (i.e., fluorescent dyes). Our previous study showed that the mixing performance could be detected solely from the electrical measurement. In this paper, we employ electromagnetic micromixers to investigate the correlation between electrical and mechanical behaviours in the mixer system. This work contemplates the “anti-reciprocity” concept by providing a theoretical insight into the measurement of the mixer system; the work explains the data interdependence between the electrical point impedance (voltage per unit current) and the mechanical velocity. This study puts the electromagnetic micromixer theory on a firm theoretical and empirical basis.

Silver Nanoprism Enhanced Colorimetry for Precise Detection of Dissolved Oxygen

Dissolved oxygen (DO) content is an essential indicator for evaluating the quality of the water body and the main parameter for water quality monitoring. The development of high-precision DO detection methods is of great significance. This paper reports an integrated optofluidic device for the high precision measurement of dissolved oxygen based on the characteristics of silver nanoprisms. Metal nanoparticles, especially silver nanoprisms, are extremely sensitive to their surroundings. In glucose and glucose oxidase systems, dissolved oxygen will be transformed into H₂O₂, which affects the oxidation and erosion process of nanoprisms, then influences the optical properties of nanoparticles. By detecting the shift in the plasma resonance peak of the silver nanoparticles, the dissolved oxygen (DO) content can be determined accurately. Great reconfigurability is one of the most significant advantages of the optofluidic device. By simply adjusting the flow rate ratio between the silver nanoprisms flow and the water sample flow, real-time continuous adjustment of the detection ranges of DO from 0 to 16 mg/L can be realized dynamically. The detection limit of this device is as low as 0.11 µM (3.52 µg/L) for DO measurement. Thus, the present optofluidic system has a wide range of potential applications in fields of biomedical analyses and water sensing.

Versatile hybrid acoustic micromixer with demonstration of circulating cell-free DNA extraction from sub-ml plasma samples

Acoustic micromixers have attracted considerable attention in the last years since they can deliver high mixing efficiencies without the need for movable components. However, their adoption in the academic and industrial microfluidics community has been limited, possibly due to the reduced flexibility and accessibility of previous designs since most of them are application-specific and fabricated with techniques that are expensive, not widely available and difficult to integrate with other manufacturing technologies. In this work, we describe a simple, yet highly versatile, bubble-based micromixer module fabricated with a combination of low-cost rapid prototyping techniques. The hybrid approach enables the integration of the module into practically any substrate and the individual control of multiple micromixers embedded within the same monolithic chip. The module can operate under static and continuous flow conditions showing enhanced mixing capabilities compared to similar devices. We show that the system is capable of performing cell-free DNA extractions from small volumes of blood plasma (≤500 μl) with up to a ten-fold increase in capture efficiency when compared to control methods.

Continuous Ultrasonic Reactors: Design, Mechanism and Application

Ultrasonic small scale flow reactors have found increasing popularity among researchers as they serve as a very useful platform for studying and controlling ultrasound mechanisms and effects. This has led to the use of these reactors for not only research purposes, but also various applications in biological, pharmaceutical and chemical processes mostly on laboratory and, in some cases, pilot scale. This review summarizes the state of the art of ultrasonic flow reactors and provides a guideline towards their design, characterization and application. Particular examples for ultrasound enhanced multiphase processes, spanning from immiscible fluid-fluid to fluid-solid systems, are provided. To conclude, challenges such as reactor efficiency and scalability are addressed.

Acoustic mixing in a dome-shaped chamber-based SAW (DC-SAW) device

The use of an open droplet system for surface acoustic wave (SAW)-based applications has been limited by droplet instability at high input power. This study introduces a dome-shaped chamber-based SAW (DC-SAW) device for the first time, which can be fabricated simply using a single adhesive tape and a drop of ultraviolet-curable material without soft lithography processes. The dome-shaped chamber device with a contact angle of 68° enables the maximizing of the effect of SAW transmitted at a refraction angle of roughly 22°, negating the droplet instability. The DC-SAW device was applied to acoustic mixing to estimate its capability. Acoustic mixing of two different fluids (i.e., deionized water and fluorescent particle suspension) was demonstrated in the dome-shaped chamber device. Moreover, the effect of flow rate and applied voltage on mixing performance was estimated. With the decreasing flow rate and increasing applied voltage, mixing performance was enhanced. At an applied voltage of 20 V, mixing indices were higher than 0.9 at a total flow rate of 300 μl min^-1.

Synergistic effects of the alternating application of low and high frequency ultrasound for particle synthesis in microreactors

Ultrasound (US) is a promising method to address clogging and mixing issues in microreactors (MR). So far, low frequency US (LFUS), pulsed LFUS and high frequency US (HFUS) have been used independently in MR for particle synthesis to achieve narrow particle size distributions (PSD). In this work, we critically assess the advantages and disadvantages of each US application method for the case study of calcium carbonate synthesis in an ultrasonic microreactor (USMR) setup operating at both LFUS (61.7 kHz, 8 W) and HFUS (1.24 MHz, 1.6 W). Furthermore, we have developed a novel approach to switch between LFUS and HFUS in an alternating manner, allowing us to quantify the synergistic effect of performing particle synthesis under two different US conditions. The reactor was fabricated by gluing a piezoelectric plate transducer to a silicon microfluidic chip. The results show that independently applying HFUS and LFUS produces a narrower PSD compared to silent conditions. However, at lower flow rates HFUS leads to agglomerate formation, while the reaction conversion is not enhanced due to weak mixing effects. LFUS on the other hand eliminates particle agglomerates and increases the conversion due to the strong cavitation effect. However, the required larger power input leads to a steep temperature rise in the reactor and the risk of reactor damage for long-term operation. While pulsed LFUS reduces the temperature rise, this application mode leads again to the formation of particle agglomerates, especially at low LFUS percentage. The proposed application mode of switching between LFUS and HFUS is proven to combine the advantages of both LFUS and HFUS, and results in particles with a unimodal narrow PSD (one order of magnitude reduction in the average size and span compared to silent conditions) and negligible rise of the reactor temperature.

Versatile Microfluidic Mixing Platform for High- and Low-Viscosity Liquids via Acoustic and Chemical Microbubbles

Microfluidic mixers have been extensively studied due to their wide application in various fields, including clinical diagnosis and chemical research. In this paper, we demonstrate a mixing platform that can be used for low- and high-viscosity liquid mixing by integrating passive (utilizing the special circulating crossflow characteristics of a zigzag microstructure and cavitation surfaces at the zigzag corners) and active (adding an acoustic field to produce oscillating microbubbles) mixing methods. By exploring the relationship between the active and passive mixing methods, it was found that the microbubbles were more likely generated at the corners of the zigzag microchannel and achieved the best mixing efficiency with the acoustically generated microbubbles (compared with the straight channel). In addition, a higher mixing effect was achieved when the microchannel corner angle and frequency were 60° and 75 kHz, respectively. Meanwhile, the device also achieved an excellent mixing effect for high-viscosity fluids, such as glycerol (its viscosity was approximately 1000 times that of deionized (DI) water at 25 °C). The mixing time was less than 1 s, and the mixing efficiency was 0.95 in the experiment. Furthermore, a new microbubble generation method was demonstrated based on chemical reactions. A higher mixing efficiency (0.97) was achieved by combining the chemical and acoustic microbubble methods, which provides a new direction for future applications and is suitable for the needs of lab-on-a-chip (LOC) systems and point-of-care testing (POCT).

Numerical Study of Bubble Breakup in Fractal Tree-Shaped Microchannels

Hydrodynamic behaviors of bubble stream flow in fractal tree-shaped microchannels is investigated numerically based on a two-dimensional volume of fluid (VOF) method. Bubble breakup is examined in each level of bifurcation and the transition of breakup regimes is discussed in particular. The pressure variations at the center of different levels of bifurcations are analyzed in an effort to gain further insight into the underlying mechanism of bubble breakup affected by multi-levels of bifurcations in tree-shaped microchannel. The results indicate that due to the structure of the fractal tree-shaped microchannel, both lengths of bubbles and local capillary numbers decrease along the microchannel under a constant inlet capillary number. Hence the transition from the obstructed breakup and obstructed-tunnel combined breakup to coalescence breakup is observed when the bubbles are flowing into a higher level of bifurcations. Compared with the breakup of the bubbles in the higher level of bifurcations, the behaviors of bubbles show stronger periodicity in the lower level of bifurcations. Perturbations grow and magnify along the flow direction and the flow field becomes more chaotic at higher level of bifurcations. Besides, the feedback from the unequal downstream pressure to the upstream lower level of bifurcations affects the bubble breakup and enhances the upstream asymmetrical behaviors.

Focusing surface acoustic waves assisted electrochemical detector in microfluidics

This article demonstrates a novel electrochemical detection device. The device is composed by two focusing interdigital transducers for exciting focused surface acoustic waves by applying an AC signal, a three-electrode system for electrochemical measurement, and a liquid pool for holding liquid on a LiNbO₃ wafer. The amperometry current of ferrocenecarboxylic acid and potassium phosphate buffer solution is used to characterize the detection sensitivity. Two experiments are carried out to optimize the device design. The result shows that the two focusing interdigital transducers with arc degree 30° and distance 5 mm can remarkably enhance the liquid mixing rate. Under this condition, the oxidation current is about 27 times larger than that without surface acoustic wave stirring.

Acoustically Driven Micromixing: Effect of Transducer Geometry

The ability to drive efficient micromixing on a microfluidic platform is crucial for a wide range of lab-on-a-chip applications. Here, we investigate the ability of acoustic waves generated on different geometric surfaces (concave and convex) to enhance the micromixing efficiency in droplet acoustomicrofluidic systems, and, concomitantly, to reduce the power consumption in these devices for a given performance requirement. Quite counterintuitively, we observe that although the acoustic streaming velocity, which scaled inversely with the droplet size, tended to be generally lower (by approximately 45%) when the flow is generated by transducers with convex surfaces compared to those with concave surfaces, the mixing efficiency is disproportionately higher: compared to pure diffusional mixing in the absence of the acoustic forcing, the mixing efficiency due to the acoustically driven convection increased by up to 25% and 43% on these respective surfaces. As such, the mixing enhancement cannot simply be attributed to an increase in the convective flow arising from the acoustic forcing. Rather, we observe the mixing enhancement to be due to the stronger chaotic advection arising in the transducer with the convex surface due to its diverging acoustic field into the droplet.

Acoustofluidic Micromixing Enabled Hybrid Integrated Colorimetric Sensing, for Rapid Point-of-Care Measurement of Salivary Potassium

The integration of microfluidics with advanced biosensor technologies offers tremendous advantages such as smaller sample volume requirement and precise handling of samples and reagents, for developing affordable point-of-care testing methodologies that could be used in hospitals for monitoring patients. However, the success and popularity of point-of-care diagnosis lies with the generation of instantaneous and reliable results through in situ tests conducted in a painless, non-invasive manner. This work presents the development of a simple, hybrid integrated optical microfluidic biosensor for rapid detection of analytes in test samples. The proposed biosensor works on the principle of colorimetric optical absorption, wherein samples mixed with suitable chromogenic substrates induce a color change dependent upon the analyte concentration that could then be detected by the absorbance of light in its path length. This optical detection scheme has been hybrid integrated with an acoustofluidic micromixing unit to enable uniform mixing of fluids within the device. As a proof-of-concept, we have demonstrated the real-time application of our biosensor format for the detection of potassium in whole saliva samples. The results show that our lab-on-a-chip technology could provide a useful strategy in biomedical diagnoses for rapid analyte detection towards clinical point-of-care testing applications.

High-speed imaging of ultrasound driven cavitation bubbles in blind and through holes

The interest in application of ultrasonic cavitation for cleaning and surface treatment processes has increased greatly in the last decades. However, not much is known about the behavior of cavitation bubbles inside the microstructural features of the solid substrates. Here we report on an experimental study on dynamics of acoustically driven (38.5 kHz) cavitation bubbles inside the blind and through holes of PMMA plates by using high-speed imaging. Various diameters of blind (150, 200, 250 and 1000 µm) and through holes (200 and 1000 µm) were investigated. Gas bubbles are usually trapped in the holes during substrate immersion in the liquid thus preventing their complete wetting. We demonstrate that trapped gas can be successfully removed from the holes under ultrasound agitation. Besides the primary Bjerknes force and acoustic streaming, the shape oscillations of the trapped gas bubble seem to be a driving force for bubble removal out of the holes. We further discuss the bubble dynamics inside microholes for water and Cu²⁺ salt solution. It is found that the hole diameter and partly the type of liquid media influences the number, size and dynamics of the cavitation bubbles. The experiments also showed that a large amount of the liquid volume inside the holes can be displaced within one acoustic cycle by the expansion of the cavitation bubbles. This confirmed that ultrasound is a very effective tool to intensify liquid exchange processes, and it might significantly improve micro mixing in small structures. The investigation of the effect of ultrasound power on the bubble density distribution revealed the possibility to control the cavitation bubble distribution inside the microholes. At a high ultrasound power (31.5 W) we observed the highest bubble density at the hole entrances, while reducing the ultrasound power by a factor of ten shifted the bubble locations to the inner end of the blind holes or to the middle of the through holes.

A Novel Thermal Bubble Valve Integrated Nanofluidic Preconcentrator for Highly Sensitive Biomarker Detection

In this study, we developed a new immunosensor that can achieve an ultralow detection limit and high sensitivity. This new device has an electrokinetic trapping (EKT)-based nanofluidic preconcentrator, which was integrated with oscillating bubble valves, to trap concentrated antigen and immunobeads. During the immunoassay process, oscillating bubbles rapidly grew and acted as control valves and to block the microchannel. Thereafter, the trapped preconcentrated antigen plug and antibody-coated nanobeads were preserved in the region between these two valves. Finally, the antigen concentration was quantitatively analyzed by a real-time measurement of Brownian diffusion of the immunobeads. In this work, the test sample used was C-reactive protein (CRP) which is a risk indicator of coronary heart disease and atherosclerosis.

An acoustofluidic trap and transfer approach for organizing a high density single cell array

We demonstrate a hybrid microfluidic system that combines fluidic trapping and acoustic switching to organize an array of single cells at high density. The fluidic trapping step is achieved by balancing the hydrodynamic resistances of three parallel channel segments forming a microfluidic trifurcation, the purpose of which was to capture single cells in a high-density array. Next, the cells were transferred into adjacent larger compartments by generating an array of streaming micro-vortices to move the cells to the desired streamlines in a massively parallel format. This approach can compartmentalize single cells with efficiencies of ≈67% in compartments that have diameters on the order of ∼100 um, which is an appropriate size for single cell proliferation studies and other single cell biochemical measurements.

Micro/nano acoustofluidics: materials, phenomena, design, devices, and applications

Acoustic actuation of fluids at small scales may finally enable a comprehensive lab-on-a-chip revolution in microfluidics, overcoming long-standing difficulties in fluid and particle manipulation on-chip. In this comprehensive review, we examine the fundamentals of piezoelectricity, piezoelectric materials, and transducers; revisit the basics of acoustofluidics; and give the reader a detailed look at recent technological advances and current scientific discussions in the discipline. Recent achievements are placed in the context of classic reports for the actuation of fluid and particles via acoustic waves, both within sessile drops and closed channels. Other aspects of micro/nano acoustofluidics are examined: atomization, translation, mixing, jetting, and particle manipulation in the context of sessile drops and fluid mixing and pumping, particle manipulation, and formation of droplets in the context of closed channels, plus the most recent results at the nanoscale. These achievements will enable applications across the disciplines of chemistry, biology, medicine, energy, manufacturing, and we suspect a number of others yet unimagined. Basic design concepts and illustrative applications are highlighted in each section, with an emphasis on lab-on-a-chip applications.