Using three-phase flow of immiscible liquids to prevent coalescence of droplets in microfluidic channels: criteria to identify the third liquid and validation with protein crystallization

Coalescence of immiscible droplets in liquid environments

HYPOTHESIS

Droplet coalescence process is important in many applications and has been studied extensively when two droplets are surrounded by gas. However, the coalescence dynamics would be different when the two droplets are surrounded by an external viscous liquid. The coalescence of immiscible droplets in liquids has not been explored.

EXPERIMENTS

In the present research, the coalescence of two immiscible droplets in low- and high-viscosity liquids is investigated and compared with their miscible counterparts experimentally. The coalescence dynamics is investigated via high-speed imaging, and theoretical models are proposed to analyze the growth of the liquid bridge.

FINDINGS

We find that, the liquid bridge r evolves differently due to the constraint from the triple line in the bridge region, which follows r∝t2/3 for low-viscosity surroundings. While for high-viscosity surroundings, the liquid bridge grows at a constant velocity ur which varies with the surrounding viscosity μs as [Formula: see text] . In the later stage of the bridge growth, the bridge evolution again merges with the well-established power-law regime r∝t1/2, being either in low or high-viscosity liquids. Moreover, a new inertia-viscous-capillary timescale is proposed, which unifies the combined influence of inertia, viscous, and capillary forces on the evolution of the liquid bridge in liquid environments, highlighting the joint role of inertia and viscous resistance in the coalescence process.

Microfluidic Valves for Selective on-Chip Droplet Splitting at Multiple Sites

We describe a microfluidic system for control of droplet division at two locations using a T-junction and expansion channel which are placed one after another. Droplets generated at a standard T-junction are introduced into the droplet division section of the microchannel. In the first set of experiments, the droplet division section consists of two consecutive identical T-junctions branching from the main channel. With this geometry, we were able to produce daughter droplets only at the first junction while there was no droplet division at the second junction. Resistive network analysis is used to redesign the microchannel geometry with an expansion channel in place of the second junction, to have the same quantity of flow entering in both the junctions. We observed five different regimes of droplet breakup, namely, (1) no droplet breakup in both junctions, (2) droplet breakup in the first junction, (3) droplet breakup in both junctions with higher daughter droplet volume in the first junction, (4) daughter droplet volume higher in the second junction, and (5) intermittent droplet breakup in both the junctions. Under specific flow conditions, droplet interaction with both the junctions is similar. We then showed design requirements for location of microvalves, simulated by deformation of the main channel wall and by experiments to break the droplet.

Manipulation of gas-liquid-liquid systems in continuous flow microreactors for efficient reaction processes

Gas-liquid-liquid flow in microreactors holds great potential towards process intensification of operation in multiphase systems, particularly by a precise control over the three-phase contact patterns and the associated mass transfer enhancement. This work reviews the manipulation of gas-liquid-liquid three-phase flow in microreactors for carrying out efficient reaction processes, including gas-liquid-liquid reactions with catalysts residing in either liquid phase, coupling of a gas-liquid reaction with the liquid-liquid extraction, inert gas assisted liquid-liquid reactions and particle synthesis under three-phase flow. Microreactors are shown to be able to provide well-defined flow patterns and enhanced gas-liquid/liquid-liquid mass transfer rates towards the optimized system performance. The interplay between hydrodynamics and mass transfer, as well as its influence on the overall microreactor system performance is discussed. Meanwhile, future perspectives regarding the scale-up of gas-liquid-liquid microreactors in order to meet the industrial needs and their potential applications especially in biobased chemicals and fuels synthesis are further addressed.

Continuous Generation of Millimeter-Sized Glycine Crystals in Non-Seeded Millifluidic Slug Flow

Millimeter-sized α-glycine crystals were generated from continuous non-seeded cooling crystallization in slug flow. The crystallization process is composed of three steps in sequence: slug formation, crash-cooling nucleation, and growth. Stable uniform slugs of three different aspect ratios (slug length/tubing inner diameter) were formed, by adjusting the flow rates of both the solution and air streams. Besides supersaturation, the slug aspect ratio can also affect primary nucleation outcome. Stable slug flow can accommodate a relative supersaturation (C/C*) of up to 1.5 without secondary nucleation. Large glycine crystals can grow to millimeter size within 10 min, inside millimeter-sized slugs without reducing the slug quality.

Simple and Precise Counting of Viable Bacteria by Resazurin-Amplified Picoarray Detection

Simple, fast, and precise counting of viable bacteria is fundamental to a variety of microbiological applications such as food quality monitoring and clinical diagnosis. To this end, agar plating, microscopy, and emerging microfluidic devices for single bacteria detection have provided useful means for counting viable bacteria, but they also have their limitations ranging from complexity, time, and inaccuracy. We present herein our new method RAPiD (Resazurin-Amplified Picoarray Detection) for addressing this important problem. In RAPiD, we employ vacuum-assisted sample loading and oil-driven sample digitization to stochastically confine single bacteria in Picoarray, a microfluidic device with picoliter-sized isolation chambers (picochambers), in <30 s with only a few minutes of hands-on time. We add AlamarBlue, a resazurin-based fluorescent dye for bacterial growth, in our assay to accelerate the detection of "microcolonies" proliferated from single bacteria within picochambers. Detecting fluorescence in picochambers as an amplified surrogate for bacterial cells allows us to count hundreds of microcolonies with a single image taken via wide-field fluorescence microscopy. We have also expanded our method to practically test multiple titrations from a single bacterial sample in parallel. Using this expanded "multi-RAPiD" strategy, we can quantify viable cells in E. coli and S. aureus samples with precision in ∼3 h, illustrating RAPiD as a promising new method for counting viable bacteria for microbiological applications.

A microfluidics platform for combinatorial drug screening on cancer biopsies

Screening drugs on patient biopsies from solid tumours has immense potential, but is challenging due to the small amount of available material. To address this, we present here a plug-based microfluidics platform for functional screening of drug combinations. Integrated Braille valves allow changing the plug composition on demand and enable collecting >1200 data points (56 different conditions with at least 20 replicates each) per biopsy. After deriving and validating efficient and specific drug combinations for two genetically different pancreatic cancer cell lines and xenograft mouse models, we additionally screen live cells from human solid tumours with no need for ex vivo culturing steps, and obtain highly specific sensitivity profiles. The entire workflow can be completed within 48 h at assay costs of less than US$ 150 per patient. We believe this can pave the way for rapid determination of optimal personalized cancer therapies.

Biocompatibility of fluids for multiphase drops-in-drops microfluidics

This paper addresses the biocompatibility of fluids and surfactants in the context of microfluidics and more specifically in a drops-in-drops system for mammalian cell based drug screening. In the drops-in-drops approach, three immiscible fluids are used to manipulate the flow of aqueous microliter-sized drops; it enables merging of drops containing cells with drops containing drugs within a Teflon tube. Preliminary tests showed that a commonly-used fluid and surfactant combination resulted in significant variability in gene expression levels in Jurkat cells after exposure to a drug for four hours. This result led to further investigations of potential fluid and surfactant combinations that can be used in microfluidic systems for medium to long-term drug screening. Results herein identify a fluid combination, HFE-7500 and 5-cSt silicone oil + 0.25% Abil EM180, which enabled the drops-in-drops approach; this combination also allowed gene expression at normal levels comparable with the conventional drug screening in both magnitude and variability.

Oscillatory multiphase flow strategy for chemistry and biology

Continuous multiphase flow strategies are commonly employed for high-throughput parameter screening of physical, chemical, and biological processes as well as continuous preparation of a wide range of fine chemicals and micro/nano particles with processing times up to 10 min. The inter-dependency of mixing and residence times, and their direct correlation with reactor length have limited the adaptation of multiphase flow strategies for studies of processes with relatively long processing times (0.5-24 h). In this frontier article, we describe an oscillatory multiphase flow strategy to decouple mixing and residence times and enable investigation of longer timescale experiments than typically feasible with conventional continuous multiphase flow approaches. We review current oscillatory multiphase flow technologies, provide an overview of the advancements of this relatively new strategy in chemistry and biology, and close with a perspective on future opportunities.

A microfluidic study of liquid-liquid extraction mediated by carbon dioxide

Liquid-liquid extraction is an important separation and purification method; however, it faces a challenge in reducing the energy consumption and the environmental impact of solvent (extractant) recovery. The reversible chemical reactions of switchable solvents (nitrogenous bases) with carbon dioxide (CO2) can be implemented in reactive liquid-liquid extraction to significantly reduce the cost and energy requirements of solvent recovery. The development of new effective switchable solvents reacting with CO2 and the optimization of extraction conditions rely on the ability to evaluate and screen the performance of switchable solvents in extraction processes. We report a microfluidic strategy for time- and labour-efficient studies of CO2-mediated solvent extraction. The platform utilizes a liquid segment containing an aqueous extractant droplet and a droplet of a solution of a switchable solvent in a non-polar liquid, with gaseous CO2 supplied to the segment from both sides. Following the reaction of the switchable solvent with CO2, the solvent becomes hydrophilic and transfers from the non-polar solvent to the aqueous droplet. By monitoring the time-dependent variation in droplet volumes, we determined the efficiency and extraction time for the CO2-mediated extraction of different nitrogenous bases in a broad experimental parameter space. The platform enables a significant reduction in the amount of switchable solvents used in these studies, provides accurate temporal characterization of the liquid-liquid extraction process, and offers the capability of high-throughput screening of switchable solvents.

Bubble Meets Droplet: Particle-Assisted Reconfiguration of Wetting Morphologies in Colloidal Multiphase Systems

Wetting phenomena are ubiquitous in nature and play key functions in various industrial processes and products. When a gas bubble encounters an oil droplet in an aqueous medium, it can experience either partial wetting or complete engulfment by the oil. Each of these morphologies can have practical benefits, and controlling the morphology is desirable for applications ranging from particle synthesis to oil recovery and gas flotation. It is known that the wetting of two fluids within a fluid medium depends on the balance of interfacial tensions and can thus be modified with surfactant additives. It is reported that colloidal particles, too, can be used to promote both wetting and dewetting in multifluid systems. This study demonstrates the surfactant-free tuning and dynamic reconfiguration of bubble-droplet morphologies with the help of cellulosic particles. It further shows that the effect can be attributed to particle adsorption at the fluid interfaces, which can be probed by interfacial tensiometry, making particle-induced transitions in the wetting morphology predictable. Finally, particle adsorption at different rates to air-water and oil-water interfaces can even lead to slow, reentrant wetting behavior not familiar from particle-free systems.

Hydrogel-droplet microfluidic platform for high-resolution imaging and sorting of early larval Caenorhabditis elegans

The nematode Caenorhabditis elegans is an important model organism in research on neuroscience and development because of its stereotyped anatomy, relevance to human biology, and ease of culture and genetic manipulation. The first larval stage (L1) is of particular interest in many biological problems, including post-embryonic developmental processes and developmental decision-making, such as dauer formation. However, L1's small size and high mobility make it difficult to manipulate; particularly in microfluidic chips, which have been used to great advantage in handling larger larvae and adult animals, small features are difficult to fabricate and these structures often get clogged easily, making the devices less robust. We have developed a microfluidic device to overcome these challenges and enable high-resolution imaging and sorting of early larval stage C. elegans via encapsulation in droplets of a thermosensitive hydrogel. To achieve precise handling of early larval stage worms, we demonstrated on-chip production, storage, and sorting of hydrogel droplets. We also demonstrated temporary immobilization of the worms within the droplets, allowing high-resolution imaging with minimal physiological perturbations. Because of the ability to array hydrogel droplets for handling a large number of L1 worms in a robust way, we envision that this platform will be widely applicable to screening in various developmental studies.

Merging drops in a Teflon tube, and transferring fluid between them, illustrated by protein crystallization and drug screening

The ability to manipulate drops with small volumes has many practical applications. Current microfluidic devices generally exploit channel geometry and/or active external equipment to control drops. Here we use a Teflon tube attached to a syringe pump and exploit the properties of interfaces between three immiscible liquids to create particular fluidic architectures. We then go on to merge any number of drops (with volumes of micro- to nano-liters) at predefined points in time and space in the tube; for example, 51 drops were merged in a defined order to yield one large drop. Using a different architecture, specified amounts of fluid were transferred between 2 nl drops at specified rates; for example, 2.5 pl aliquots were transferred (at rates of ~500 fl s(-1)) between two drops through inter-connecting nano-channels (width ~40 nm). One proof-of-principle experiment involved screening conditions required to crystallize a protein (using a concentration gradient created using such nano-channels). Another demonstrated biocompatibility; drugs were mixed with human cells grown in suspension or on surfaces, and the treated cells responded like those grown conventionally. Although most experiments were performed manually, moderate high-throughput potential was demonstrated by mixing ~1000 different pairs of 50 nl drops in ~15 min using a robot. We suggest this reusable, low-cost, and versatile methodology could facilitate the introduction of microfluidics into workflows of many experimental laboratories.

Controlled multistep synthesis in a three-phase droplet reactor

Channel-fouling is a pervasive problem in continuous flow chemistry, causing poor product control and reactor failure. Droplet chemistry, in which the reaction mixture flows as discrete droplets inside an immiscible carrier liquid, prevents fouling by isolating the reaction from the channel walls. Unfortunately, the difficulty of controllably adding new reagents to an existing droplet stream has largely restricted droplet chemistry to simple reactions in which all reagents are supplied at the time of droplet formation. Here we describe an effective method for repeatedly adding controlled quantities of reagents to droplets. The reagents are injected into a multiphase fluid stream, comprising the carrier liquid, droplets of the reaction mixture and an inert gas that maintains a uniform droplet spacing and suppresses new droplet formation. The method, which is suited to many multistep reactions, is applied to a five-stage quantum dot synthesis wherein particle growth is sustained by repeatedly adding fresh feedstock.

Combinatorial generation of droplets by controlled assembly and coalescence

We describe a microfluidic system for generating a sequence of liquid droplets of multiple concentrations in a single experimental condition. The series of final droplets has the combination of the compositions varying periodically, with polydispersity of the size less than 8%. By utilizing the design of the microchannel geometry and the passive control of three immiscible fluids (oil, water, and air) including generation, breakup, separation and coalescence of droplets, we can change the system to generate diverse sets of combination of materials. The device can be used for testing different concentration of materials in picoliter volumes and developing a new way to deliver dynamic signals of chemicals with microfluidics.

Three-phase slug flow in microchips can provide beneficial reaction conditions for enzyme liquid-liquid reactions

Here, we introduce a solution to low stability of a two-phase slug flow with a chemical reaction occurring at the phase interface in a microfluidic reactor where substantial merging of individual reacting slugs results in the loss of uniformity of the flow. We create a three-phase slug flow by introducing a third fluid phase into the originally two-phase liquid-liquid slug flow, which generates small two-phase liquid slugs separated by gas phase. Introduction of the third phase into our system efficiently prevents merging of slugs and provides beneficial reaction conditions, such as uniform flow pattern along the whole reaction capillary, interfacial area with good reproducibility, and intensive water-oil interface renewal. We tested the three-phase flow on an enzyme hydrolysis of soybean oil and compared the reaction conversion with those from unstable two-phase slug flows. We experimentally confirmed that the three-phase slug flow arrangement provides conversions and pressure drops comparable or even better with two-phase liquid-liquid arrangements.

Simulations of droplet coalescence in simple shear flow

Simulating droplet coalescence is challenging because small-scale (tens of nanometers) phenomena determine the behavior of much larger (micrometer- to millimeter-scale) droplets. In general, liquid droplets colliding in a liquid medium coalesce when the capillary number is less than a critical value. We present simulations of droplet collisions and coalescence in simple shear flow using the free-energy binary-liquid lattice Boltzmann method. In previous simulations of low-speed collisions, droplets coalesced at unrealistically high capillary numbers. Simulations of noncoalescing droplets have not been reported, and therefore, the critical capillary number for simulated collisions was unknown. By simulating droplets with radii up to 100 lattice nodes, we determine the critical capillary number for coalescence and quantify the effects of several numerical and geometric parameters. The simulations were performed with a well-resolved interface, a Reynolds number of one, and capillary numbers from 0.01 to 0.2. The ratio of the droplet radius and interface thickness has the greatest effect on the critical capillary number. As in experiments, the critical capillary number decreases with increasing droplet size. A second numerical parameter, the interface diffusivity (Péclet number) also influences the conditions for coalescence: coalescence occurs at higher capillary numbers with lower Péclet numbers (higher diffusivity). The effects of the vertical offset between the droplets and the confinement of the droplets were also studied. Physically reasonable results were obtained and provide insight into the conditions for coalescence. Simulations that match the conditions of experiments reported in the literature remain computationally impractical. However, the scale of the simulations is now sufficiently large that a comparison with experiments involving smaller droplets (≈10 μm) and lower viscosities (≈10(-6) m(2)/s, the viscosity of water) may be possible. Experiments at these conditions are therefore needed to determine the interface thickness and Péclet number that should be used for predictive simulations of coalescence phenomena.

A microfluidic platform for evaporation-based salt screening of pharmaceutical parent compounds

We describe a microfluidic platform to screen for salt forms of pharmaceutical compounds (PCs) via controlled evaporation. The platform enables on-chip combinatorial mixing of PC and salt former solutions in a 24-well array (~200 nL/well), which is a drastic reduction in the amount of PC needed per condition screened compared to traditional screening approaches that require ~100 μL/well. The reduced sample needs enable salt screening at a much earlier stage in the drug development process, when only limited quantities of PCs are available. Compatibility with (i) solvents commonly used in the pharmaceutical industry, and (ii) Raman spectroscopy for solid form identification was ensured by using a hybrid microfluidic platform. A thin layer of elastomeric PDMS was utilized to retain pneumatic valving capabilities. This layer is sandwiched between layers of cyclic-olefin copolymer, a material with low air and solvent permeability and low Raman background to yield a physically rigid and Raman compatible chip. A solvent-impermeable thiolene layer patterned with evaporation channels permits control over the rate of solvent evaporation. Control over the rate of solvent evaporation (2-15 nL h(-1)) results in consistent, known rates of increase in the supersaturation levels attained on-chip, and increases the probability for crystalline solids to form. The modular nature of the platform enables on-chip Raman and birefringence analysis of the solid forms. Model compounds, tamoxifen and ephedrine, were used to validate the platform's ability to screen for salts. On-chip Raman analysis helped to identify six different salts each of tamoxifen and ephedrine.

Droplet-based microfluidics

Droplet-based microfluidics or digital microfluidics is a subclass of microfluidic devices, wherein droplets are generated using active or passive methods. The active method for generation of droplets involves the use of an external factor such as an electric field for droplet generation. Two techniques that fall in this category are dielectrophoresis (DEP) and electrowetting on dielectric (EWOD). In passive methods, the droplet generation depends on the geometry and dimensions of the device. T-junction and flow focusing methods are examples of passive methods used for generation of droplets. In this chapter the methods used for droplet generation, mixing of contents of droplets, and the manipulation of droplets are described in brief. A review of the applications of digital microfluidics with emphasis on the last decade is presented.

Building droplet-based microfluidic systems for biological analysis

In the present paper, we review and discuss current developments and challenges in the field of droplet-based microfluidics. This discussion includes an assessment of the basic fluid dynamics of segmented flows, material requirements, fundamental unit operations and how integration of functional components can be applied to specific biological problems.

A microfluidic platform for pharmaceutical salt screening

We describe a microfluidic platform comprised of 48 wells to screen for pharmaceutical salts. Solutions of pharmaceutical parent compounds (PCs) and salt formers (SFs) are mixed on-chip in a combinatorial fashion in arrays of 87.5-nanolitre wells, which constitutes a drastic reduction of the volume of PC solution needed per condition screened compared to typical high throughput pharmaceutical screening approaches. Nucleation and growth of salt crystals is induced by diffusive and/or convective mixing of solutions containing, respectively, PCs and SFs in a variety of solvents. To enable long term experiments, solvent loss was minimized by reducing the thickness of the absorptive polymeric material, polydimethylsiloxane (PDMS), and by using solvent impermeable top and bottom layers. Additionally, well isolation was enhanced via the incorporation of pneumatic valves that are closed at rest. Brightfield and polarized light microscopy and Raman spectroscopy were used for on-chip analysis and crystal identification. Using a gold-coated glass substrate and minimizing the thickness of the PDMS control layer drastically improved the signal-to-noise ratio for Raman spectra. Two drugs, naproxen (acid) and ephedrine (base), were used for validation of the platform's ability to screen for salts. Each PC was mixed combinatorially with potential SFs in a variety of solvents. Crystals were visualized using brightfield polarized light microscopy. Subsequent on-chip analyses of the crystals with Raman spectroscopy identified four different naproxen salts and five different ephedrine salts.

Fabrication of advanced particles and particle-based materials assisted by droplet-based microfluidics

Recent advances in the fabrication of complex particles and particle-based materials assisted by droplet-based microfluidics are reviewed. Monodisperse particles with expected internal structures, morphologies, and sizes in the range of nanometers to hundreds of micrometers have received a good deal of attention in recent years. Due to the capability of generating monodisperse emulsions and of executing precise control and operations on the suspended droplets inside the microchannels, droplet-based microfluidic devices have become powerful tools for fabricating complex particles with desired properties. Emulsions and multiple-emulsions generated in the microfluidic devices can be composed of a variety of materials including aqueous solutions, gels, polymers and solutions containing functional nanoparticles. They are ideal microreactors or fine templates for synthesizing advanced particles, such as polymer particles, microcapsules, nanocrystals, and photonic crystal clusters or beads by further chemical or physical operations. These particles are promising materials that may be applicable for many fields, such as photonic materials, drug delivery systems, and bio-analysis. From simple to complex, from spherical to nonspherical, from polymerization and reaction crystallization to self-assembly, this review aims to help readers be aware of the many aspects of this field.

Polymer based chemical delivery to multichannel capillary patterned cells

In order to match the controllability of traditional pipetting with the advantages of microfluidics, we introduce the concept of polymer based chemical delivery to multichannel capillary patterned cells. Here we demonstrate that UV polymerized hydrogel can be used as a miniature pipet to deliver picolitre chemical quantities to multichannel capillary patterned cells.

Microfluidics using spatially defined arrays of droplets in one, two, and three dimensions

Spatially defined arrays of droplets differ from bulk emulsions in that droplets in arrays can be indexed on the basis of one or more spatial variables to enable identification, monitoring, and addressability of individual droplets. Spatial indexing is critical in experiments with hundreds to millions of unique compartmentalized microscale processes--for example, in applications such as digital measurements of rare events in a large sample, high-throughput time-lapse studies of the contents of individual droplets, and controlled droplet-droplet interactions. This review describes approaches for spatially organizing and manipulating droplets in one-, two-, and three-dimensional structured arrays, including aspiration, laminar flow, droplet traps, the SlipChip, self-assembly, and optical or electrical fields. This review also presents techniques to analyze droplets in arrays and applications of spatially defined arrays, including time-lapse studies of chemical, enzymatic, and cellular processes, as well as further opportunities in chemical, biological, and engineering sciences, including perturbation/response experiments and personal and point-of-care diagnostics.

A single-molecule enzymatic assay in a directly accessible femtoliter droplet array

The enzyme assay in a femtoliter chamber array is a simple and efficient method for concentrating the reaction product; it greatly improves the detection sensitivity down to the single-molecule level. However, in previous methods, controlling the initiation and termination of the reaction in each chamber is difficult once enclosed. Furthermore, the recovery of the enzyme and product is also difficult. To overcome these drawbacks, we developed a femtoliter droplet array in which the individual droplets are fixed on the substrate and are directly accessible from outside. A hydrophilic-in-hydrophobic micropatterned surface was used for the preparation of the droplets. When the aqueous solution on the surface is exchanged with oil, the hydrophilic surface retains the aqueous solution, and more than 10(6) dome-shaped droplets that are usable for further assay can be prepared simultaneously. The curvature radius of the droplet obeys the Young-Laplace equation, and the volume can be precisely controlled by the micropipette, which applies pressure into the droplet. Changing the pressure makes the addition, collection, and exchange of the aqueous content for individual droplets possible. Using these advantages, we successfully measured the kinetic parameters of the single-molecule enzyme β-galactosidase and rotary motor protein F(1)-ATPase enclosed in a droplet.

Plasmonic nanoshell synthesis in microfluidic composite foams

The availability of robust, scalable, and automated nanoparticle manufacturing processes is crucial for the viability of emerging nanotechnologies. Metallic nanoparticles of diverse shape and composition are commonly manufactured by solution-phase colloidal chemistry methods, where rapid reaction kinetics and physical processes such as mixing are inextricably coupled, and scale-up often poses insurmountable problems. Here we present the first continuous flow process to synthesize thin gold "nanoshells" and "nanoislands" on colloidal silica surfaces, which are nanoparticle motifs of considerable interest in plasmonics-based applications. We assemble an ordered, flowing composite foam lattice in a simple microfluidic device, where the lattice cells are alternately aqueous drops containing reagents for nanoparticle synthesis or gas bubbles. Microfluidic foam generation enables precisely controlled reagent dispensing and mixing, and the ordered foam structure facilitates compartmentalized nanoparticle growth. This is a general method for aqueous colloidal synthesis, enabling continuous, inherently digital, scalable, and automated production processes for plasmonic nanomaterials.

Partial wetting gas-liquid segmented flow microreactor

A microfluidic reactor strategy for reducing plug-to-plug transport in gas-liquid segmented flow microfluidic reactors is presented. The segmented flow is generated in a wetting portion of the chip that transitions downstream to a partially wetting reaction channel that serves to disconnect the liquid plugs. The resulting residence time distributions show little dependence on channel length, and over 60% narrowing in residence time distribution as compared to an otherwise similar reactor. This partial wetting strategy mitigates a central limitation (plug-to-plug dispersion) while preserving the many attractive features of gas-liquid segmented flow reactors.

Evolution of catalysts directed by genetic algorithms in a plug-based microfluidic device tested with oxidation of methane by oxygen

This paper uses microfluidics to implement genetic algorithms (GA) to discover new homogeneous catalysts using the oxidation of methane by molecular oxygen as a model system. The parameters of the GA were the catalyst, a cocatalyst capable of using molecular oxygen as the terminal oxidant, and ligands that could tune the catalytic system. The GA required running hundreds of reactions to discover and optimize catalyst systems of high fitness, and microfluidics enabled these numerous reactions to be run in parallel. The small scale and volumes of microfluidics offer significant safety benefits. The microfluidic system included methods to form diverse arrays of plugs containing catalysts, introduce gaseous reagents at high pressure, run reactions in parallel, and detect catalyst activity using an in situ indicator system. Platinum(II) was identified as an active catalyst, and iron(II) and the polyoxometalate H(5)PMo(10)V(2)O(40) (POM-V2) were identified as active cocatalysts. The Pt/Fe system was further optimized and characterized using NMR experiments. After optimization, turnover numbers of approximately 50 were achieved with approximately equal production of methanol and formic acid. The Pt/Fe system demonstrated the compatibility of iron with the entire catalytic cycle. This approach of GA-guided evolution has the potential to accelerate discovery in catalysis and other areas where exploration of chemical space is essential, including optimization of materials for hydrogen storage and CO(2) capture and modifications.

Designed pneumatic valve actuators for controlled droplet breakup and generation

The dynamic breakup of emulsion droplets was demonstrated in double-layered microfluidic devices equipped with designed pneumatic actuators. Uniform emulsion droplets, produced by shearing at a T-junction, were broken into smaller droplets when they passed downstream through constrictions formed by a pneumatically actuated valve in the upper control layer. The valve-assisted droplet breakup was significantly affected by the shape and layout of the control valves on the emulsion flow channel. Interestingly, by actuating the pneumatic valve immediately above the T-junction, the sizes of the emulsion droplets were controlled precisely in a programmatic manner that produced arrays of uniform emulsion droplets in various sizes and dynamic patterns.

Microfluidic Droplet Technique for In Vitro Directed Evolution

Increasingly over the past two decades, biotechnologists have been exploiting various molecular technologies for high-throughput screening of genes and their protein products to isolate novel functionalities with a wide range of industrial applications. One particular technology now widely used for these purposes involves directed evolution, an artificial form of evolution in which genes and proteins are evolved towards new or improved functions by imposing intense selection pressures on libraries of mutant genes generated by molecular biology techniques and expressed in heterologous systems such as Escherichia coli. Most recently, the rapid development of droplet-based microfluidics has created the potential to dramatically increase the power of directed evolution by increasing the size of the libraries and the throughput of the screening by several orders of magnitude. Here, we review the methods for generating and controlling droplets in microfluidic systems, and their applications in directed evolution. We focus on the methodologies for cell-based assays, in vitro protein expression and DNA amplification, and the prospects for using such platforms for directed evolution in next-generation biotechnologies.

Droplet-based microfluidic synthesis of anisotropic metal nanocrystals

A droplet-based microfluidic method for the preparation of anisotropic gold nanocrystal dispersions is presented. Gold nanoparticle seeds and growth reagents are dispensed into monodisperse picoliter droplets within a microchannel. Confinement within small droplets prevents contact between the growing nanocrystals and the microchannel walls. The critical factors in translating macroscale flask-based methods to a flow-based microfluidic method are highlighted and approaches are demonstrated to flexibly fine tune nanoparticle shapes into three broad classes: spheres/spheroids, rods, and extended sharp-edged structures, thus varying the optical resonances in the visible-near-infrared (NIR) spectral range.

Microfluidic emulsions with dynamic compound drops

We demonstrate a new class of microfluidic emulsion where the 'drops' of the emulsion are dynamic reversible bubble-drop pairs, with potential applications in microfluidic technology for chemical synthesis, molecular separations and screening.

Manipulation of gel emulsions by variable microchannel geometry

In this article we investigate the morphology and manipulation of monodisperse emulsions at high dispersed phase volume fractions (gel emulsions) in a microfluidic environment. Confined monodisperse gel emulsions self-organize into well-ordered droplet arrangements, which may be stable or metastable, depending on the geometry of the confining microchannel. Three arrangements are considered, in which the droplets are aligned in a single file, a two row, or a three row arrangement. We explore the potential for induced transitions between these distinct droplet arrangements as a tool for droplet-based microfluidic processing. Transitions are readily achieved by means of localized (geometrical) features in channel geometry, however the onset of the transition is strongly dependent on the subtleties of the microfluidic system, e.g. volume fraction, droplet size, and feature dimensions. The transitions can be achieved via fixed channel features or, when the continuous phase is a ferrofluid, by a virtual channel constriction created using a magnetic field.

High-molecular-weight polymers for protein crystallization: poly-gamma-glutamic acid-based precipitants

Protein crystallization has been revolutionized by the introduction of high-throughput technologies, which have led to a speeding up of the process while simultaneously reducing the amount of protein sample necessary. Nonetheless, the chemistry dimension of protein crystallization has remained relatively undeveloped. Most crystallization screens are based on the same set of precipitants. To address this shortcoming, the development of new protein precipitants based on poly-gamma-glutamic acid (PGA) polymers with different molecular-weight ranges is reported here: PGA-LM (low molecular weight) of approximately 400 kDa and PGA-HM (high molecular weight) of >1,000 kDa. It is also demonstrated that protein precipitants can be expanded further to polymers with much higher molecular weight than those that are currently in use. Furthermore, the modification of PGA-like polymers by covalent attachments of glucosamine substantially improved their solubility without affecting their crystallization properties. Some preliminary PGA-based screens are presented here.

ABO, D blood typing and subtyping using plug-based microfluidics

A plug-based microfluidic approach was used to perform multiple agglutination assays in parallel without cross-contamination and using only microliter volumes of blood. To perform agglutination assays on-chip, a microfluidic device was designed to combine aqueous streams of antibody, buffer, and red blood cells (RBCs) to form droplets 30-40 nL in volume surrounded by a fluorinated carrier fluid. Using this approach, proof-of-concept ABO and D (Rh) blood typing and group A subtyping were successfully performed by screening against multiple antigens without cross-contamination. On-chip subtyping distinguished common A1 and A2 RBCs by using a lectin-based dilution assay. This flexible platform was extended to differentiate rare, weakly agglutinating RBCs of A subtypes by analyzing agglutination avidity as a function of shear rate. Quantitative analysis of changes in contrast within plugs revealed subtleties in agglutination kinetics and enabled characterization of agglutination of rare blood subtypes. Finally, this platform was used to detect bacteria, demonstrating the potential usefulness of this assay in detecting sepsis and the potential for applications in agglutination-based viral detection. The speed, control, and minimal sample consumption provided by this technology present an advance for point of care applications, blood typing of newborns, and general blood assays in small model organisms.